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Mechanics of Materials Cutting
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leads to the work piece material being cut differently and makes it leave the ground surface either fractured or produces ductile streaks When the protrusion height is within the critical depth of the cut region, plastic deformation occurs by a ploughing action and produces ductile streaks However, when the protrusion height is beyond the critical depth of cut region, fractured and deep cracks will be left on the ground surface as a result of an excessive Hertzian surface pressure exerted by the abrasive grains A large number of ductile streaks were observed on Ge than on Si and glass when grinding with resinoid bonded wheels The model of Kitajima et al [51] is based on the combination of two theories: (i) the brittle material softened by the high temperature at the cutting point becomes plastically deformable, and can be machined as in any other material, (ii) the Hertzian surface pressure of two bodies in contact with each other produces stresses and deformations that cause micro cracks which lead to the breakdown of the grains, causing brittle material erosion Kitajima et al [51] showed evidence of plastic flow with Al2O3, Si3N4 and SiC along grinding streaks
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Fig 346: The original Konig s model showing sharp and flattened dull grains that cause a brittle fracture due to
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high in feeds and ductile cutting as a result of the frictional heat between lamellas [49]
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Konig s model modified by Zhong and Venkatesh [50] to show uneven protrusions out of the bond representing the grain depth of cut Abrasive grains on the right side that protrude slightly within the critical depth of cut region producing ductile streaks, whereas the grains on the left side protrude more than the critical depth of cut region producing fractures and deep cracks
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The above model explains the results obtained during partial mode grinding on CNC machining centres [45] [50] that make the process cost effective especially for the ophthalmic industries
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1 Kalpakjian, S, Manufacturing Engineering and Technology 3rd Edition, Addision-Wesley Publishing Company, New York, 1995 2 Courtesy of Michigan Technological University, John W Sutherland Online available at http://wwwmfgmtuedu/cyberman/machining/intro/mechanics/indexhtml 3 Boothroyd, G, Fundamentals of Metal Machining and Machine Tools, International Student Edition, McGrawHill International Book Company, Tokyo, 1981 4 Shaw, MC, Metal Cutting Principles, 2nd Edition, University Press Inc, New York, Oxford, 2005 5 Groover, MP, Fundamentals of Modern Manufacturing: Materials, Processes and Systems, Prentice-Hall International, Inc, USA, 1996 6 Online available at http://wwwtoolingucom 7 Trent, EM and Wright PK, Metal Cutting, 3rd Edition, Butterworth-Heinemann, USA, 2000 8 Merchant, ME, J Appl Phys, p 16 (5), 267(a) and p 318 (b) 9 Armargo EJA, and Brown RH, The Machining of Metals, Prentice-Hall Inc, New Jersey, 1969 10 Venkatesh, VC, Chandrasekaran, H, Experimental Techniques in Metal Cutting, Prentice-Hall of India Pvt Ltd, New Delhi, 1987 11 Pai, DM, Ratterman, E and Shaw, MC, Grinding swarf, Wear, 1989, 131: pp 329 339
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12 Malkin, S, Grinding Technology: Theory and Application of Machining with Abrasives, Ellis Horwood Limited, England, 1989 13 Reichenbach, GS, Mayer, Jr JE, Kalpakcioglu, S and Shaw, MC, The role of chip thickness in grinding, Trans ASME, 1956, 18: pp 847 850 14 Mayer, JE and Fang, GP, Effect of grit depth of cut on strength of ground ceramics, Annals of the CIRP, 1994, 43(1): pp 309 312 15 Shaw, MC and Outwater, JO, Surface temperatures in grinding, Trans ASME, 1952, pp 74: 73 16 Pandit, SM and Sathyanarayanan, G, Surface roughness and specific energy with progress of cut in grinding, SME Technical Paper, 1984, MR84-531: pp 1 18 17 Shaw, MC, The size effect in metal cutting, Sadhana, The Indian Academy of Sciences, 2003, 28(5): pp 875 896 18 Taniguchi, N, The state of the art of nanotechnology for processing of ultra precision and ultra fine products, Precision Engineering, 1994, 16(1): pp 5 24 19 Backer, WR, Marshall, ER and Shaw, MC, The size effect in metal cutting, Trans ASME, 1952, pp 74: 61 20 Shaw, MC, Precision finishing, Annals of the CIRP, 1995, 44(1): pp 343 348 21 Shaw, MC, Energy conversion in cutting and grinding, Annals of the CIRP, 1996, 45(1): pp 101 104 22 Metzger, JL, Superabrasive Grinding, Butterworth & Co (Publishers) Ltd, London, 1986 23 Chandrasekar, S, Shaw, MC and Bushan, B, Comparison of grinding and lapping of ferrites and metals Machining of ceramic materials and components, 1987, ASME: pp 45 52 24 Shaw, MC, A simplified approach to workpiece temperatures in fine grinding, Annals of the CIRP, 1990, 39(1): pp 345 347 25 Klocke, F and Eisenbl tter, G, Dry cutting Keynote paper, Annals of the CIRP, 1997, 46(2): pp 519 526 26 Jackson, MJ, Wear of perfectly sharp abrasive grinding wheels, SME technical paper, 2002, MR02pp 157, 1 8 27 Savington, D, Maximizing the grinding process, SME technical paper, 2001, MR01-140, pp 1 12 28 Holz, R and Sauren, J, Grinding with Diamond and CBN, Winter Diamond and CBN Tools Catalogue, Ernst Winter & Sohn Diamantwerkzeuge GmbH & Co, 1988 29 Jackson M J, Hyde LJ, Model analysis of tetrahedral machine tool structure, ICAMT 2004, Kuala Lumpur May 11 13, 2004, pp 394 400 30 Komanduri, R, On material removal mechanisms in finishing of advanced ceramics and glasses, Annals of the CIRP, 1996, 45(1): pp 509 513 31 Lawn, BR, and Evans, AG A model for crack initiation in elastic-plastic indentation fields, Journal of Material Science, 1977, 12: pp 2195 2199 32 Lawn, BR, Evans, AG and Marshall, DB, Elastic-plastic indentation damage in ceramics: the median/ radial crack system, Journal of American Ceramics Society, 1980, 63: pp 574 581 33 Inasaki, I, Grinding of hard and brittle materials, Annals of the CIRP, 1987, 36(2): pp 463 471 34 Lawn, BR and Wilshaw, R, Indentation fracture: principles and applications, Journal of Material Science, 1975, 10: pp1049 1081 35 Komanduri, R, Lucca, DA and Tani, Y, Technological advances in fine abrasive processes, Keynote Paper, Annals of the CIRP, 1997, 46(2): pp 545 596 36 Tabor, D, The hardness of solids, Proc of the Institute of Physics, F Physics in Technology, 1970, 1: pp 145 179
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