Shaping the cutting ability of grinding wheels with zone-diversified structure

This article presents the results of experimental tests aimed at determining the influence of shaping the microgeometry of particular functional zones (rough and finish grinding) of the grinding wheel active surface in the dressing cut and what effect this would have on the results of the internal cylindrical grinding process of steel 100Cr6. Single-pass grinding processes and the grinding wheel used in them are described. Grinding wheels with zone-diversified structure, made from abrasive grains along the basis of Al2O3 (white fused alumina 99A and microcrystalline sintered corundum), are characterized, and the construction of a special device for precise shaping of the conic chamfer on the grinding wheel active surface is presented. The experimental test results form the basis for determining the influence of the chief dressing parameters (grinding wheel peripheral speed v(sd), dressing axial feed rate v(fd)) on the selected machined surface roughness parameters (Ra, Rz, RSm, Rdq), surface bearing ratio and grinding power P in the internal cylindrical traverse grinding process. It was proven that the most advantageous grinding results are obtained when using different dressing parameters for the conic rough grinding zone and the cylindrical finish grinding zone of the grinding wheel. When shaping the grinding wheel conic chamfer, increased values of the dressing feed rate v(fd(cone)) need to be used in order to reduce the grinding power. The most advantageous parameter values for describing the machined surface roughness were obtained with low values of axial table dressing feed rate v(fd(cylinder)), providing precise alignment and sharpening of the grinding wheel active surface cylindrical zone.