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The overall objective was to develop the high speed grinding technology for grinding with vitrified bonded CBN wheels with a cutting speed of Vc=230m/s. A suitable machine tool system with hydrostatic grinding wheel and dresser spindles and an integrated balancing unit were designed. The grinding wheels were developed for increased wheel speed and an adequate wheel mounting system was used.
Once the system was completed and running, an optimized grinding strategy was developed. The influences of the grinding parameters on the surface integrity of the workpiece were investigated and assessed. A monitoring system using Acoustic Emission for the detection of grinding burn was developed.
At the end of the project an advanced machine tool system for CBN high-speed grinding is available. It was shown that the high-speed grinding technology offers the possibility of better using the potential of the superabrasive CBN. The grinding results are improved, as a high specific material removal rate can be reached with even small grit size grinding wheels, resulting in a good surface roughness, reduced grinding forces, good workpiece roundness and reduced wheel wear. Furthermore, positive influences on the surface integrity, especially the fatigue behaviour, were measured.
The knowledge gathered during the project was exploited for some new applications, e.g. CBN grinding of concave camshafts for high-end automobile engines.
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