The effects of spark-out on flatness in steel grinding

Abstract

Spark-out produces parts with high flatness and smooth surfaces in grinding. Elastic deformation on wheels and workpieces diminishes during spark-out, and this increases dimensional accuracy. Despite its potential for high-quality productions, spark-out is time-consuming. While examining the thermal distortion on ground surface in spark-out, this study develops a strategy to achieve high flatness on ground surfaces. A numerical model is developed to analyze the surface deformations in dry grinding. Additionally, exactly how set depth of cut (SDOC), wheel properties and cutting fluid affects surface profile during spark-out is examined by experiments. Results of the study demonstrate that concave distortion of the profiles is reduced during spark-out with dry grinding, and the profiles turn convex with wet grinding of steel with a white alumina wheel. Optimum flatness is generally achieved, when a smaller SDOC and cutting fluid are used in the experiments.

Keywords:

• grinding
• spark-out
• flatness
• elastic recovery

Acknowledgement

Ted Knoy is appreciated for his editorial assistance.