Forecasting of operational indicators of grinding tools with the controlled form and orientation of abrasive grains

Abstract

The interconnection of the abrasive grain front angle parameter with the form, orientation and wear out parameters is investigated. The form of the abrasive grains was estimated by means of form coefficient which represents the relation of diameters of the spheres described around contours of grains, to diameters of the spheres entered in them. The spatial orientation angle of the abrasive grains was defined between main (i.e. the biggest) axis of the grains and the cutting plane. It is established that, depending on an orientation angle at increase in a form coefficient of the abrasive grains can be either an increase or a decrease in the values of their front angles. In most cases, with an increase in a form coefficient of the oriented grinding grains (at orientation angles [theta]=10°-125°) the growth of their front angles is fixed. At tangential orientation of grains ([theta]=0°) and at the close directions of orientation ([theta]=135°-180°) the return picture is observed. Also established that the longer the abrasive grain wears along the main axis and located in the tool body, the larger is its front angle. Besides that, the front angles of the abrasive grains reach the maximum positive values at orientation angles [theta]=2.5°-45°.Dependence of tension in grains during the work with parameters of their form, orientation and depth of embedment in the bundle is investigated. It was found that for all orientation angles of grains their tension significantly increases with an increase in their form coefficient. Besides that it is confirmed that the deeper the grain is in the bundle, the lower the tension is there. Also found that tension is minimal when the grains are tangential orientated. Further on increase the option of the grains in the direction of action of the cutting force follows. Such option of orientation is the most rational both from the point of view of minimization of tension, and for ensuring rational sizes of front angles of the abrasive grains. The rational angle of grain orientation for cutting disc are in range [theta]=65°-75°. The joint analysis of dependences of front angles and tension in grains from factors of their form and orientation allows the prediction of operating characteristics of grinding tools at the design stage for specific tasks and processing conditions.