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A new dimension for high-speed grinding

: Ferlemann, F.; König, W.

Industrial diamond review : IDR 25 (1991), Nr.5, S.237-241 : Abb.
ISSN: 0019-8145
ISSN: 0959-8294
Fraunhofer IPT ()
balancing optimization; CBN layer; high-frequency spindle; high-speed grinding; hub optimization of cooling; hydraulic balancing; influence of workpiece hardeness; optimization calculation; power loss calculation

Investigating high-speed grinding up to 500m/s had to await new developments in wheel design, machine design and a balancing system. An efficient realisation of cutting speeds up to 500m/s requires wheel diameters from 200mm to 350mm and spindle speeds of 30.000 r.p.m. Recording of the vibration behavior of available high-frequency spindles revealed that balancing of the spindle/ grinding wheel system is practical only at operating speed. Power measurements at different peripheral speeds and with various wheel diameters have shown that a sharp increase in the power losses can be measured particulary in the supersonic range. This occurs because of increasing air friction losses at the surface of the rotating wheel. The smallest possible wheel diameter should always be selected. In addition, there are power losses due to the use of a coolant and wheel cleaning. Our test results show that the flow rates and pressures of the coolant wheel flushing fluid are far more important than in the p ast. The grinding forces were reduced by up to 50% during surface grinding of 16MnCr5 steel by increasing the wheel speed to 340m/s. Finally, the development of a cylindrical grinding machine for wheel peripheral speeds up to 500m/s was described.