PRINCIPLES OF ABRASIVE PROCESSING
by Dr. Milton Shaw
Oxford University Press, 1996
574 pages, illus.
$229 (may be subject to change)
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The best book on the materials science and mechanics of abrasives technology in print anywhere.
This is a work by Dr. Milton Shaw who has compiled what researchers know about abrasive processing. The most thorough and comprehensive book ever published of Abrasives, a landmark publication in abrasives technology with lots of technical information without the formulas or clutter of technical data. Written by one of founders of current abrasives technology.
__________TABLE OF CONTENTS__________
- INTRODUCTION — PAGES 1-12
Grinding Overview, Special Topics, Absolute Versus Relative Solutions, Systems Approach
- ABRAIVE TOOLS — PAGES 13-42
Common Abrasives - Types and Surface Morphology
Superabrasives - Surface Morphology and Boron Carbide, Commercial Friability Tests, Bonded Products, Coated Products
- SINGLE GRIT PERFORMANCE — PAGES 43-88
Grit Stength - static and dynamic tests with discussion, Single Grit Wear Tests - literature reviw and rubbing wear tests, Fly Miling Tests - plain fly milling, high-speed, low-pressure tests, over cut milling and face milling , Bench Tests, Specific Energy - experimental results, Sharpened Spherical Grits
- FORM AND FINISHING GRINDING MECHANICS — PAGES 89-106
Hardness Model of Chip Formation, Undeformed Chip Thickness, Active Grit Density, C Ratio of Scratch Width to Scratch Depth, Wheel-Work Contact Length, Equilavent Chip Thickness
- FORM AND FINISH GRINDING PERFORMANCE —PAGES 107-163
Grinding Forces and Power, Size Effect in FFG, Mean Force per Grit, Measurement of Wheel Grade, Wheel Grading Tests Based on Elastic Modulus, Wheel-Work Deflection, Trueing and Dressing and Conditioning, The Interrupted Grinding Principle, Grinding Swarf, Grinding with Axial Feed
- ABRASIVE CUT-OFF —PAGES 164-188
Econimcs, Representative G Versus D Curves, Mechanics, Wheel Speed, General Observations, Machine and Operating Considerations, Optimization, Oscillation and Rotation, Competitition for Abrasive Cut-Off, Friction Sawing, Precision Crack-off
- CONDITIONING OF SLABS AND BILLETS —PAGES 189-200
Mechanics, Wear, Economics, Role of Abrasive Type, High-Speed Constant-Power Conditioning, The Future
- VERTICAL SPINDLE SURFACE GRINDING —PAGES 201-212
Chip Geometry, Cost Optimization, Optimum Work Area, Wheel Wear
- GRINDING TEMPERATURES —PAGES 213-260
Form and Finishing Grinding Temperatures, Conductive Heat Transfer, Jaeger, Linear Jaeger Model, The Galileo Principle, Dimensional Analysis, FFG Temperatures, Grinding with Coolant, Representative Applications, Surface Melting in Grinding, Sparks and Chips, Modeling and Simulation, Thermoelectric Measurements, Radiation Measurements, Infrared Photographic Film, Stock Removal Temperatures, Experiemental Results, Analysis
- SURFACE INTEGRITY —PAGES 261-313
Surface Finish - Factorial Experimental Design, Surface Finish Experiments, Analytical Approach, Dynamic Active Grit Density. C Area Continuity Approach, Examples, Transverse Profile Approach, Spark-Out, Tracing Direction, Chatter
Metallurgical Damage - Martensite, Transformations, Surface Grinding, Analogy, Example - Annealed Steel
Residual Stress - Measurement, Examples, Origins of Residual Grinding Stresses, Ceramics
- WHEEL LIFE —PAGES 314-336
Cluster, Overcut Fly Grinding (COFG) - Local wheel deflection, Summary
Difficult to Grind Materials - Wear-Resistant Tool Steel, Grindability of T15 Tool Steel
- GRINDING ENVIRONMENT —PAGES 337-378
Gases, Liquids, High-Speed Grinding, Inorganic Fluids for Titanium Alloys, Corrosion Inhibitors, Inorganic Solutions for Titanium, Belt Grinding of Titanium Alloys, Diamond Grinding of Titanium Alloys, Fluid Evaluation by COFG, Grinding Aids, Wheel Loading
- SPECIAL PROCESSES —PAGES 379-470
Internal Grinding - Constant Force Grinding, Honing
Creep Feed Grinding - Wheel Speed with Aluminum Oxide, Up vs Down Grinding, Cooling, Temperature Instability, Creep Feed Machines, Surface Finish, Cubic Boron Nitride
High-Efficiency Deep Grinding, Creep Feed Cylindrical Grinding, Speed Stoke Grinding
Cylindrical Grinding - CIRP Study, Wheel Wear, Wheel Life, Speed Ratio, Axial Force in Profile Grinding
Centerless Grinding - Applications, Mechanics, Machines, Optimization of Production
Belt Grinding - Contact Wheels, Belt Life, Surface Finish
Special Operations and the Future - Electrochemical Grinding, Abrasive Jet Machining, Abrasive Water Jet Cutting, Deburring, Lapping, Polishing, Burr Technology, Abrasive Flow Machining, Ultrasonic Cleaning, Superfinish Lapping, Free Abrasive Grinding, Magnetic Field Assisted Finishing, Polishing, Precision Polishing of Glass, Elastic Emission Machining, Large Optical Components
- HARD WORK MATERIALS —PAGES 471-534
Rock and Concrete - Diamond Wire Sawing, Fine Wire Sawing,Grindability of Granite, Diamond Circular Sawing of Granite, Power Analysis of Large d/D, Abrasive Cut-off, Creed Feed Grinding, Performance of Large d/D, Factorial Experimental Design of Power, Chip Storage, Wheel with Single Layer of Grits, Basalt, Communition
Ceramics - Pendulum Grinding, Creep Feed Grinding, Abrasive Cut-off, Electrolytic In-Process Dressing, Ferrite Temperatures
Glasses - Edge Grinding, Slitting of Glass, Machining of Glass, Ultrasonic Grinding
- PRECISION FINISHING —PAGES 535-566
Consequences of Small Chip Size, Single Point Diamond Turning (SPDT), Ultra-Precision Diamond Grinding (UPDG), Continuous Electrolytic Dressing, “Ductile Regime” Removal, Subsurface Crack Detection, Mean Radial Force per Grit, Volume Deformed in Fine Grinding, The Possibility of Indentation Involving Pulverization, The Special Situation of Glass
Excerpts from Principles of Abrasive Processing...
....As in the case of the regular abrasives, the surface morphology of superabrasives plays an important role in their performance. The superiority of synthetic diamonds over natural diamonds lies in the ability to control the structure, shape and friability of the grains during their production. A comprehensive SEM study of a number of different types of superabrasives has been made and represenative results are given below...
...On both cube and octahedral faces (of MBG diamond grits), surface features resembling a network of streams can be seen. Such networks arise during the last stages of the diamond growth process, when some of the catalyst freezes epitaxially upon the diamond face, and diamond formation ceases where the catalyst has frozen. However, nondiamond carbon migrate to regions where the catalyst is still molten and convert to diamond, thereby forming ridges on the diamond faces. This process continues until all the catalyst has frozen. This surface feature is observed on all types of synthetic diamonds exept the polycrystalline line variety.
Taken from the superabrasives section in the Abrasive Tools chapter.
Principles of Abrasive Processes is available for $229(subject to change without notice)
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© Ted Giese 2003