Grinding Wheel Pockets for Burr-Free High-Speed Profile Grinding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In profile grinding of metallic workpieces, particularly for creating chip grooves in drilling or milling tools, existing grinding wheels face challenges with burr formation on groove edges at high feed speeds and require excessive coolant/lubricant supply, limiting processing speed due to centrifugal forces and air movements.
Innovation Solution
Incorporating a pattern of pockets over the entire circumference of the grinding wheel that capture side cheeks with mouth openings, which interrupts the grinding surface and enhances coolant/lubricant absorption and dust/chip management, maintaining effective coolant supply at high speeds without compromising machining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high feed speeds are used in profile grinding, then productivity increases, but burr formation occurs on groove edges
Solution Approach 1:
The grinding wheel surface is segmented into multiple pockets distributed over the entire circumference, each pocket acting as an independent coolant reservoir. This segmentation allows localized coolant supply to different zones of the grinding gap, preventing burr formation while maintaining high feed speeds across the entire wheel width.
Solution Approach 2:
Coolant is stored in advance within the pockets before grinding contact occurs. As the wheel rotates and pockets enter the grinding zone, the pre-stored coolant is immediately available to suppress burr formation at the groove edges, eliminating the need for reactive coolant adjustment during high-speed operation.
2Reliability
If large quantities of coolant/lubricant are supplied to prevent structural transformations, then workpiece quality improves, but centrifugal forces and air movements increase, limiting feed rate
Solution Approach 1:
Instead of uniformly distributing coolant across the entire wheel width, the invention provides localized coolant supply only at specific pockets where grinding contact occurs. This local quality approach ensures adequate cooling and lubrication at the grinding interface while minimizing overall coolant consumption and reducing centrifugal effects on the workpiece.
Solution Approach 2:
The pockets are designed with porous structures that enable controlled coolant release. The porous material allows coolant to be absorbed and then released gradually at the grinding interface, maintaining effective coolant supply for workpiece quality while reducing the total coolant volume required and minimizing adverse centrifugal effects.
3Manufacturing precision
If continuous grinding surface is maintained from one side cheek to the other, then machining accuracy is preserved, but coolant supply efficiency decreases at high speeds
Solution Approach 1:
The continuous grinding surface is maintained for machining accuracy, while the coolant supply system is segmented into multiple discrete pockets. This segmentation allows coolant to be delivered efficiently at specific locations along the grinding interface, improving coolant supply efficiency without compromising the continuity of the grinding surface and machining accuracy.
Solution Approach 2:
Coolant supply occurs periodically as pockets rotate into the grinding zone, rather than requiring continuous coolant flow across the entire wheel width. This periodic action at high speeds improves coolant supply efficiency by synchronizing coolant delivery with the grinding contact points, while the continuous grinding surface maintains machining accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design prevents burr formation on groove edges, maintains sufficient coolant/lubricant in the grinding gap, reduces thermal stress, and allows for increased feed speeds while maintaining machining accuracy and economic efficiency.
Implementation Method 1
The grinding wheels used in this grinding process operate at peripheral speeds of over 100 m/s, e.g., approximately 120 m/s. The resulting centrifugal forces and air movements near the grinding wheel require a significant excess of coolant/lubricant (CSM) to be supplied to the grinding gap.
Implementation Method 2
The wheel body is dressed to a predetermined circumferential cross-sectional contour and equipped with side cheeks, wherein the circumferential cross-sectional contour is prepared so that its circumferential section plunges to its full depth into a workpiece blank (40), in that the grinding surface extends continuously from one side cheek to the other. Even if the grinding wheel can carry coolant/lubricant (CSM) into the grinding gap due to the porosity of the wheel body being tailored to the grinding process...
Data Source
Figure 1
Figure 1A~1B
Figure 2~4
AI summary
This document describes a grinding wheel designed for the form grinding of profiled recesses in metallic workpieces, particularly for profile grinding of flutes for drilling or milling tools. In this grinding process, the grinding gap formed by the entire contour of the grinding wheel's outer circumferential surface is supplied with coolant/lubricant by directing a concentrated jet of coolant/lubricant onto the grinding wheel. The grinding wheel has a body equipped with side walls that can be dressed to a predetermined circumferential cross-sectional contour. The circumferential cross-sectional contour is designed to allow its entire circumference to penetrate a workpiece blank to its full depth, with the grinding surface extending continuously from one side wall to the other.To achieve higher feed rates even with difficult-to-machine materials, without requiring rework of the ground grooves, a pattern of pockets is incorporated into the entire circumference of the grinding wheel body. These pockets are designed to engage at least the side walls of the wheel body and have an opening in the area of the circumferential cross-sectional contour. The grinding wheel can be used particularly economically because the pocket pattern is designed to remain intact during the dressing of the grinding wheel contour.