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Prior to the development of continuous dressing operations, the grinding efficiency of vitrified grinding wheels deteriorates as the sharp cutting edges become blunt due to the formation of wear flats Dressing is essentially a sharpening operation designed to generate a specific topography on the working surface of the grinding wheel The use of high power lasers is being explored as a noncontact cleaning and dressing technique Jackson used a high power laser to clean metal chips from the surface of the grinding wheel and to dress the wheel by causing phase transformations to occur on the surface of vitrified grinding wheel High power lasers that are currently used as a non-contact type machining tool for various manufacturing applications such as welding, drilling, cutting, etc, can also be used as a non-contact type dressing tool The salient features of a laser include high intensity fluency, directionality, and spatial coherence, which can be used to process hard and brittle materials efficiently Laser induced thermal processing leads to effect such as melting, vaporization, and plasma formation on the material of the grinding wheel, which can be exploited during the dressing procedure During laser dressing, the wheel surface topography of the grinding wheel is modified by melting of the material and subsequent re-solidification of a portion of the molten layer During the process, rapid heating and cooling induces cracks in the re-solidified layer The microcracks help remove the re-melted layer during grinding after a few initial grinding strokes, which then exposes new cutting edges In laser dressing, the grinding wheel is subjected to a high power laser intensity, which produces Fig 332: Arrangement of the laser cleaning procedure craters on the surface and also induces microcracks in the re-cast molten layer [29] There are several inherent advantages associated with the use of lasers for dressing applications Laser dressing is a very fast process, and it can be easily automated Also, selective removal of the clogged material alone is possible, and the desired surface structure (roughness, grain morphology and porosity) can be generated Furthermore, consistent dressing conditions can be produced by the use of lasers, and this can help achieve grinding reproducibility As the laser beam can be delivered using a fibre optic cable, remote dressing operation without discontinuation of the grinding process during laser dressing is possible Thus, the downtime in the grinding operation associated with conventional methods can either be eliminated or substantially reduced in laser dressing
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35 MATERIAL REMOVAL MECHANISMS
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Komanduri [30] has reported that due to their extreme brittleness and hardness, material removal of hard and brittle materials be it by machining, grinding or by polishing is mostly by brittle fracture This enables high material removal rates and results in a more efficient process, provided that these
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Mechanics of Materials Cutting
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defects do not extend below the finished surface and that there is sufficient material left for finishing them to the desired form, size accuracy and finish The material removal mechanism by this mode has been analogous to the indentation sliding analysis conducted by Lawn et al [31][32] The schematic diagram of the indentation process in brittle materials is shown in Figure 333(a) The following summarizes the behaviour of brittle materials when they are progressively indented (loading and unloading) which leads to brittle fracture on the surface: (i) the sharp point of the indenter produces an elastic deformation zone, (ii) at some threshold, a deformation-induced flow suddenly develops into a small crack, termed a median crack, (iii) an increase in the load causes further, a steady growth of the median crack, (iv) upon unloading, the median crack begins to close, (v) upon complete removal, the lateral vents continue their extension, towards the specimen surface and may accordingly lead to chipping (vi) Inasaki [33] cited the work of Taniguchi in comparing the behaviour of materials when indenters with different tip radii are impressed on brittle and ductile materials Localized deformation and fracture developed on these surfaces depending on the geometry of indenter and the loading conditions as shown in Figure 333(b) For ductile materials, such as metal, plastic deformation is mostly induced,
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Fig 333: (a) Inasaki s schematic illustration [33] of the point indentation process showing the development of
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plastic deformation, median cracks and lateral cracks leading to the chipping of hard and brittle materials (b) Lawn s different indenter geometry and loading conditions provide different effects on ductile and brittle materials [34]
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