A method of the measurement of temperature and grinding force components during flute grinding of solid carbide end mills was presented. The tests were performed using two diamond grinding wheels: with a resin bond (S1) and with a metal bond (S2). A diamond grinding wheel of 1A1 type and a...

This study presents a comprehensive analysis of defect detection in the manufacturing process of solid carbide milling tools. The creep-feed flute grinding technique was used to fabricate a milling tool, with cutting force signals recorded and examined using recurrence analysis and conventional statistical methods. The analysis identified four distinct dynamic fluctuations (cutting force amplitude jumps), which showed a direct correlation with the formation of microcracks on the flute surface. These jumps exhibited varying levels of reduction, ranging from 5% to 22% in amplitude. A detailed investigation, including recurrence plots and recurrence quantification analysis (RQA) with a moving-window approach, revealed that several recurrence indicators, such as the recurrence rate (RR), determinism (DET), and maximum diagonal line length (L_MAX), were highly effective in detecting microcracks, as their values significantly deviated from the reference level. These results were compared with conventional statistical analysis, and interestingly, the recurrence methods demonstrated greater sensitivity, successfully detecting additional very small cutting force jumps that conventional statistical methods could not identify.

This paper presents a comprehensive analysis of the flute grinding process in end cutters, focusing on the influence of machining parameters on recurrence indicators. Recurrence quantification analysis (RQA) was employed to assess the dynamic behavior, regularity, and predictability of the process. Based on experimental data, a grinding force model was developed, along with mathematical formulations of the recurrence indicators. Leveraging these models, a novel parameter, the dominant index was proposed to identify which cutting parameters have the greatest impact on the RQA measures. The results reveal that cutting speed exerts a dominant influence on both the grinding force and recurrence metrics. However, for specific indicators, the feed rate emerges as the prevailing factor. The study also demonstrates a strong correlation between cutting parameters and the harmonic content of the grinding force signal. Furthermore, increasing cutting speed was found to generally stabilize the process, whereas variations in feed rate may either enhance or deteriorate machining stability.

Artykuł Wpływ siły szlifowania na odkształcenia sprężyste długich frezów pełnowęglikowych | Mechanik Miesięcznik Naukowo-Techniczny

Artykuł Dynamiczna symulacja obróbki pięcioosiowej z wykorzystaniem wirtualnej maszyny w systemie NX * | Mechanik Miesięcznik Naukowo-Techniczny

The paper discusses the use of a grinding wheel with sintered microcorundum admixture in the plunge grinding process of nitrided EI961 steel. The study presents results on the influence of machining parameters on the components of grinding force and surface roughness. The tests were carried out using a CNC grinder equipped with a piezoelectric force measurement system during grinding. The results showed a significant impact of the feed rate during grinding and dressing, and to a lesser extent the grinding speed, on the values of grinding forces. The main factor affecting surface roughness parameters is the dressing feed rate. The developed mathematical models enable prediction of process outcomes and optimization of technological parameters.