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The size of an abrasive grain is identified by a number, which is normally a function of the mesh width of the sieve size either in microns or mesh openings per inch Figure 42 shows the equivalent
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grain size used by the FEPA (microns), ASTME 11 (inches), ISO and DIN (microns) standards for both diamond and CBN wheels In the metric system (microgrit size), the smaller the number, the smaller is the grit size However, the coding is reversed in the imperial system wherein a smaller number represents a coarser grit size
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The grade of a grinding wheel refers to its strength in holding the abrasive grains in the wheel This is largely dependent on the amount of bonding material used As the amount of bonding material is increased, the linking structure between the grains becomes larger which makes the wheel act harder A hard wheel has a stronger bond than does a soft wheel The type and the amount of bonding material in the wheel also influence the overall strength In standard marking systems, the grade of the grinding wheel is labelled as A Z (soft to hard)
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The structure of a grinding wheel represents the grain spacing and is a measure of the porosity of a bonded abrasive wheel Figure 42 illustrates the structure of a grinding wheel showing bigger pore areas (voids) in the open structure than in the medium and dense structure Porosity allows clearance space for the grinding chips to be removed for a proper cutting action during grinding operation If this clearance space is too small, the chip will remain in the wheel, causing what is known as wheel loading A loading cutting wheel heats up and is not efficient in the cutting action When this happens, a frequent dressing is needed to remove loaded workpiece particles on the wheel On the other hand, it is inefficient to have too large a space, as there will be too few cutting edges A dense structure has a strong grit holding power than does an open structure Some porosity is essential in bonded wheels to provide not only a clearance for the minute chips being produced but also to provide a cooling effect; otherwise, they could interfere with the grinding process In standard marking systems, the structure of the wheel is labelled by numbers Smaller numbers denote an open structure, whereas larger numbers represents denser structures Internationally, effort has been constantly made to minimize the variability of the grit spacing and the projection height of the grain in order to make the grinding process more predictable [19] [20] As illustrated in Figure 44, grain depths of cut and the space between grains are higher in (a) than in (b), and these are distinct advantages for effective grinding involving less loading and heat generation
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While the percentages of grains, bonds and their spacing in the wheel determine the wheel s structure, the concentration indicates the volume of diamond or CBN in the grinding layer It is defined as the percentage weight of the abrasive grit per cubic unit of the grinding layer For diamond, the basic value of C100 means that every cm3 of layer volume contains 44 carats of diamond (1 ct = 02 g,
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Fig 42: Equivalent international standard of grit sizes for diamond and cubic boron nitride used by the FEPA,
US, DIN and ISO standards compared to WINTER designations [17]: (a) a dense structure, (b) a medium structure and (c) an open structure
Fig 43: The structure of a grinding wheel [18]
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Grinding wheel Space between grains
Grinding wheel Space between grains
Grain projection
Grain projection
Binder Ideal grain structure
Binder
Typical single-layer grinding wheel (b)
Fig 44: Schematic diagrams showing (a) the ideal grain structure with a controlled grain spacing and projection
height and (b) a typical single-layer grinding wheel with random grain spacing and projection height [21]
diamond density = 353 g/cm3), which is equivalent to 25% by volume of the diamond content in the grinding layer As a general rule, for selection of the desired concentration, high concentrations are suitable for small contact areas and low concentrations for large contact areas [17]
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