Handbook of Machining with Grinding Wheels by loan D. Marinescu Mike Hitchiner Eckart Uhlmann W. Brian Rowe Ichiro Inasaki 596 pages, illustrated with graphs and charts ISBN 1-57444-671-1 $179 plus shipping (subject to change) ORDER/INFORMATION REQUEST or call 724-282-6210 for phone order. The first comprehensive book on the use of grinding wheels in over a decade. Includes details for applications of diamond and CBN superabrasives as well as conventional abrasives. Written by well known experts from Japan, the US, and Europe, this is a complete discussion of the use of grinding wheels in production applications covering topics ranging from the basics of material removal to design and control of machine tools. For the first time a single publication covering the lastest data on proper use of centerless, ID, OD, and surface grinding machine tools. Application notes throughout show practical, real-world examples of a variety of common materials. A totally new book, this work reflects the state-of-the-art on topics such as control of chatter, workpiece burn, use of CBN, machine tool sensors, and much more.

NOTES FROM THE PREFACE Called the "Handbook of Machining with Grinding Wheels because the borders between grinding and other operations such as superfinishing, lapping, polishing, and flat honing are no longer distinct. Machining with grinding wheels extends from high-removal rate processes into the domains of ultra-high accuracy and superfinishing. This book aims to explore some of the new "transition operations,"... This book presents a wide range of abrasive machining technology in fundamental and application terms. The emphasis is on why things happen as they do, rather than a how-to-do-it approach. The topics covered in this book cover a range of abrasive machining processes with grinding wheels, making this probably the most complete book regarding all kinds of grinding operations." ...loan D. Marinescu Toledo, 2006

THE AUTHORS Ioan D. Marinescu professor of mechanical, industrial, and manufacturing engineering at the University of Toledo director of the Precision Micro?Machining Center of the College of Engineering (www.eng.utoledo.edu/pmmc) member of numerous international professional organizations: JSPE, SME, ASME, ASPE, CIRP, IDA, ASAT, and NAMRI. author of more than 15 books and over 300 technical and scientific papers. founded his own company, Advanced Manufacturing Solutions Co., LLC, a company that specializes in consulting, R&D, manufacturing, and trade (www.interams.com) Mike Hitchiner doctorate in 1982 at the University of Oxford for research in grinding and machining with cubic boron nitride (CBN) and diamonds. technology manager for precision grinding applications for North America, as well as projects throughout Asia and Europe for . Saint?Gobain Abrasives (SGA) and its affiliate companies e Eckart Uhlmann director of the Fraunhofer?Institute for Production Systems and Design Technology IPK professor of machine tools and manufacturing technology at the Institute for Machine Tools and Factory Management of the Technical University in Berlin, Germany. doctorate in engineering on "Creep Feed Grinding of High?Strength Ceramic Materials." professional memberships in the Berlin Wissenschaftskommission, the Verein Deutscher Ingenieure, and the International Institution for Production Engineering Research. honorary doctorate from Kolej Universiti Teknikal Kebangsaan, Malaysia. W. Brian Rowe experience with Austin Motor Company, Birmingham, England, and Wickman Machine Tools, Coventry, England. Ph.D. for research on the mechanics of centerless grinding and tribology. head of mechanical engineering at Liverpool John Moores University director of the Advanced Manufacturing Technology Research Laboratory (AMTREL) published with them more than 250 scientific papers, patents, and books including Design of Hydrostatic and Hybrid Bearings in 1982 and Tribology of Abrasive Machining Processes in 2004. Ichiro Inasaki Dean of the Faculty of Science and Technology, Keio University, doctorates at Keio University in 1969 and honorary Dr.?Ing. at Hanover University, Germany, in 1999. fellow of the Japan Society of Mechanical Engineers, the Japan Society of Precision Engineering, and the Society of Manufacturing Engineers, and served as president for CIRP between 2004 and 2005. Editor of international journals including the International Journal for Manufacturing Science and Production, Machining Science and Technology, International Journal of Production Engineering and Computers, Journal of Engineering Manufacture (IMechE), and Journal of Nanotechnology and Precision Engineering for years to date. Awards from Japan Society of Mechanical Engineers in 1969, 1987, 1997, and 1999, the Japan Society for Precision Engineering in 1992 and 2005, the Japan Society for Abrasive Technology in 1980 and 1998, the Japanese Society of Tribologists in 2003, and the Society of Manufacturing Engineers (F. W. Taylor Research Medal) in 2005. His dedicated efforts have been condensed in books, publications in journals, and more than 300 papers in the field of manufacturing engineering.

TABLE OF CONTENT (ABBREVIATED) click for a more complete table of contents and other materials Part I   The Basic Process of Grinding   I Chapter 1     Introduction     3   1.1  From Craft to Science   3   1.2  Basic Uses of Grinding   4   1.3  Elements of the Grinding System   4       1.4  The Importance of the Abrasive   6   1.5  Grinding Wheels for a Purpose   7   1.6  Problem-Solving   7       References   8 Chapter 2 Grinding Parameters   9   2.1  Introduction   9       2.2  Process Parameters   11       2.3  Grinding Temperatures   18   Appendix 2.1 Drawing Form and Profile Tolerancing   21   References     21 Chapter 3 Material Removal Mechanisms     23   3.1  Significance   23       3.2  Grinding Wheel Topography   24       3.3  Determination of Grinding Wheel Topography   25       3.4  Kinematics of the Cutting Edge Engagement   29   3.5  Fundamental Removal Mechanisms   31   3.6  Material Removal in Grinding of Ductile Materials   32   3.7  Surface Formation in Grinding of Brittle/Hard Materials 35       3.8  Energy Transformation   41   References   42 Chapter 4 Grinding Wheels   45   4.1  Introduction   45       4.2  Wheel Shape Specification    46   4.3  Wheel Balance     49   4.4  Design of High?Speed Wheels     54   4.5  Bond Life   61   4.6  Wheel Mount Design   61   4.7  Wheel Design and Chatter Suppression     71     References     73 Chapter 5 The Nature of the Abrasive     75   5.1  Introduction   75   5.2  Silicon Carbide     75   5.3  Alumina (Alox)-Based Abrasives   76   5.4 Electrofused Alumina Abrasives     76   5.5  Chemical Precipitation and/or Sintering of Alumina     79   5.6  Diamond Abrasive  82   5.7  CBN   93     5.8  Grain Size Distributions   98     5.9  Future Grain Developments   99   5.10  Postscript   99   References   100 Chapter 6 Specification of the Bond   103   6.1 Introduction   103   6.2 Single-Layer Wheels   103   6.3 Electroplated (EP) Singl-Layer Wheels   103   6.4 Brazed Singl-Layer Wheels   107   6.5 Vitrified Bond Wheels for Conventional Wheels   108   6.6 Vitrified Bonds for Diamond Wheels   114   6.7 Vitrified Bonds for CBN   115   6.8  Resin Bond Wheels   118   6.9  Plastic Bonds   119   6.10  Phenolic Resin Bonds   119   6.11  Polyimide Resin Bonds   121     6.12  Metal Bonds   122   6.13.1 Rubber     124   6.13.2 Shellac     124   6.13.3 Silicate     124   References     124 Chapter 7 Dressing      127   7.1  Introduction   127   7.2  Traverse Dressing of Conventional Vitrified Wheels with Stationary Tools   127   7.3  Traverse Dressing of Superabrasive Wheels with Stationary Tools     137   7.4 Uniaxial Traverse Dressing of Conventional Wheels with Rotary Diamond Tools   138   7.5 Uniaxial Traverse Dressing of Vitrified CBN Wheels with Rotary Diamond Tools   142   7.6  Cros-Axis Traverse Dressing with Diamond Discs   149   7.8  Truing and Conditioning of Superabrasive Wheels   160   References   165 Chapter 8 Grinding Dynamics   167   8.1 Introduction   167   8.2  Forced and Regenerative Vibrations   167   8.3  The Effect of Workpiece Velocity   168   8.4  Geometrical Interference between Grinding Wheel and Workpiece   170   8.5  Vibration Behavior of Various Grinding Operations   170   8.6  Regenerative Self?Excited Vibrations   172   8.7  Suppression of Grinding Vibrations  178   8.8  Conclusions     183   References   184 Chapter 9 Grinding Wheel Wear   185   9.1  Three Types of Wheel Wear   185   9.2  Wheel Wear Mechanisms   185   9.3  Wear of the Abrasive Grains   186   9.4  Bond Wear     191   9.5  Assessment of Wheel Wear     192   References 193 Chapter 10 Coolants     195   10.1   Introduction     195   10.2   Basic Properties of Grinding Fluids   195   10.3  Types of Grinding Fluids     196   10.4  Base Materials     197   10.5  Additives     199   10.6  Application Results     201   10.7  Environmental Aspects   201   10.8  The Supply System         201   10.9   Grinding Fluid Nozzles         203   10.10   Influence of the Grinding Fluid in Grinding  206   10.10.1   Conventional Grinding     206     References  213 Chapter 11 Monitoring of Grinding Processes   11.1   The Need for Process Monitoring     217   11.2   Sensors for Monitoring Process Variables   218   11.3   Sensor for Monitoring the Grinding Wheel     228   11.4   Sensors for Monitoring the Workpiece     233   11.5  Sensors for Peripheral Systems   240     References     244 Chapter 12 Economics of Grinding   12.1   Introduction     247   12.2   A Grinding Cost Comparison Based on an Available Grinding Machine     247     12.3   A Cost Comparison Including Capital Investment     249   12.4   Cost Comparison Including Tooling     250   12.5   Grinding as a Replacement for Other Processes     251   12.6   Multitasking Machines for Hard?Turning with Grinding     252   12.7   Summary     253     References     253        Part II Application of Grinding  Processes   Chapter 13 Grinding of Ductile Materials      13.1  Introduction   257   13.2  Cast Irons   258   13.3  Steels   259   13.4  Hea-?Resistant Superalloys   263     References   265    Chapter 14 Grinding of Ceramics      14.1  Introduction   267   14.2   Background on Ceramic Materials   268   14.3   Diamond Wheels for Grinding Ceramics   271   14.4  Physics of Grinding Ceramics   274   14.5  ELID Grinding of Ceramics   278     References   282 Chapter 15 Grinding Machine Technology      15.1  The Machine Base     285   15.2  Foundations   288   15.3  Guideways   290   15.4  Slideway Configurations   290   15.5  Hydrostatic Slideways   294   15.6   Recirculating Rolling Element Slideways   297   15.7   Linear Axis Drives and Motion Control   299   15.8  Elements of AC Servodrive Ballscrew Systems   299   15.9  Linear Motor Drive Systems   305   15.10   Spindle Motors and Grinding Wheel Drives   307   15.11   Drive Arrangements for Large Conventional Wheels   307   15.12  Drive Arrangements for Small Wheel Spindle Units   312   15.13  Spindles for High?Speed Grinding   315   15.14  Miscellaneous Wheel Spindles and Drives   316   15.15  Rotary Dressing Systems   317   15.16  Power and Stiffness Requirements for Rotary Dressers   319   15.17  Rotary Dressing Spindle Examples   320   15.18  Dressing Infeed Systems   325     References   336 Chapter 16 Surface Grinding        16.1   Types of Surface Grinding Process     341   16.2   Basics of Reciprocating Grinding   341   16.3  Basics of Creep Grinding   346   16.4   Basics of Speed?Stroke Grinding   353   16.5   Successful Application of Creep Feed Grinding   356   16.6  Face Grinding   381   16.7  Fine Grinding   401     Appendix 16.1 Lapping Kinematics   407     References   412 Chapter 17 External Cylindrical Grinding   17.1  The Basic Process   417   17.2  High-Speed Grinding   421   17.3  Automotive Camlobe Grinding   431   17.4  Punch Grinding   439   17.5  Crankshaft Grinding   442   17.6  Roll Grinding   447     References   450 Chapter 18 Internal Grinding      18.1   Introduction   453   18.2   The Internal Grinding  Process   453   18.3  Abrasive Type     455   18.4  Process Parameters   458   18.5  Machine Tool Selection   466   18.6  Troubleshooting   474     References     476 Chapter 19 Centerless Grinding        19.1   The Importance of Centerless Grinding     479   19.2  Basic Process   480   19.3  Basic Relationships   485   19.4  Feed Processes   487   19.5   Centerless Wheels and Dressing Geometry   90   19.6  The Workrest   493   19.7  Speed Control   494   19.8  Machine Structure   496   19.9  High Removal Rate Grinding   501   19.10   Economic Evaluation of Conventional and CBN Wheels   506   19.11  The Mechanics of Rounding   516   19.12  Vibration Stability   527   19.13  Dynamic Stability   537   19.14   Avoiding Critical Frequencies   541   19.15  Summary and Recommendations for Rounding   543   19.16  Process Control   543   References   546 Chapter 20   Ultrasonic Assisted Grinding      20.1   Introduction   549   20.2   Ultrasonic Technology and Process Variants   549   20.3   Ultrasoni-?Assisted Grinding with Workpiece Excitation   552   20.4   Peripheral Grinding with Radial Ultrasonic Assistance   552   20.5   Peripheral Grinding with Axial Ultrasonic Assistance   555   20.6   Ultrasonic-Assisted Grinding with Excitation of the Wheel   557     References   562   Appendix 1: Glossary 563   Appendix 2: Notation and Use of SI Units     591   Use of Units   591   Examples of Correct and Incorrect Practice     591   Factors for Conversion between S1 Units and British Units (Values Rounded)   592   Index   593 TOP