Life Cycle and Sustainability of Abrasive Tools

276 Pages·2016·6.688 MB·English

by  Barbara Linke (auth.)

RWTHedition
Barbara Linke
Life Cycle and
Sustainability
of Abrasive
Tools
RWTHedition
Series editor
RWTH Aachen University, Aachen, Germany
More information about this series at http://www.springer.com/series/7858
Barbara Linke
Life Cycle and Sustainability
of Abrasive Tools
123
Barbara Linke
Department ofMechanical andAerospace
Engineering
University of California Davis
Davis, CA
USA
ISSN 1865-0899 ISSN 1865-0902 (electronic)
RWTHedition
ISBN978-3-319-28345-6 ISBN978-3-319-28346-3 (eBook)
DOI 10.1007/978-3-319-28346-3
LibraryofCongressControlNumber:2015960222
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Grinding tools are the most up-to-date and at
the same time the least known tools for
processing. [MOSE80]
Acknowledgments
This thesis was written mainly during my time as postdoc researcher at the
Werkzeugmaschinenlabor (WZL) at the RWTH Aachen University, and at the
Laboratory for Manufacturing and Sustainability (LMAS) at the University of
California Berkeley. The research on the life cycle engineering of abrasive tools
was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research
Foundation)throughtheprojectLI1939/3-1.ThankyoutotheDFGforthesupport
and the opportunity to study abroad.
I thank Prof. Klocke from the bottom of my heart for mentoring me during my
timeasresearchassociateathisinstituteandbeyond.Grindingtechnology,detailed
research,andteachingareoursharedpassion.Prof.Klocketrustedallthewhilethat
pursuing an academic career would be the right way for me to go. Thank you for
beingsuchagreatmentortomeandforintroducingmetotheinternationalresearch
community!
Professor Dornfeld earns my deepest gratitude for hosting me in his laboratory
and providing me with excellent opportunities for networking. I learned so much
from his visionary yet applied research on sustainable manufacturing.
Thank you to Prof. Karpuschewski for being a role model and inspiring me to
pursueaninternationalresearchfellowship.Iamalsogratefulforhisadviceonthis
thesis.
Dr. Busch was one of my closest discussion partners and a very great
help.Ithankhimwholeheartedly.ManythanksalsotoDr.SigwartandMr.Noichl
from Tyrolit; Dr. Hall and Dr. Arcona from Saint-Gobain Abrasives Norton;
Prof. Vollstädt and Dr. List from Vollstaedt-Diamant; Dr. Bot-Schulz and
Dr. Pähler from Saint-Gobain Abrasives; Dr. John Barry from E6; Dr. Magg from
Tesch; Mr. Danner from Elbe Schleifmittel; and Dr. Paul and Dr. Michels from
Wendt. I am thankful for all the insights into how companies secure the sustain-
abilityoftheirabrasivetoolingsystems.ThankyoutoProf.Aurichfortheinspiring
cooperation on the CIRP keynote paper on sustainability in abrasive processes.
vii
viii Acknowledgments
Iamthankfulforallthetechnicalhelpfrommyformerfaithfulstudentassistants
Seamus Laprell and Janis Thiermann, and guest researchers Sabine Mannebach,
ZhiweiZhang,andGeroCorman.SabineMs.Mannebachconductedthecasestudy
on CBN and corundum tools thoroughly.
Many thanks to Prof. Garret O’Donnell, Trinity College Dublin, Dr. Markus
Weiss, Tyrolit, Benjamin Doebbeler, Werkzeugmaschinenlabor (WZL) at the
RWTH Aachen University, and Maria Celeste Castillo, University of California
Davis for reviewing the thesis thoroughly.
IamthankfulforthecordialatmosphereattheAachenerSchleiferGroupandat
the UC Berkeley LMAS. I would like to thank Dr. Bernd Meyer, Dr. Michael
Duscha, Guido Kochs-Theisen, Peter Ritzerfeld, Dr. Dirk Friedrich, Dominik
Schluetter, Dr. Holger Groening, Dr. Moneer Helu, Dr. Margot Hutchins, and
Dr.DaeyoungKong,justtonameafewofallthegreatlaboratorymembersatboth
institutions.
Last, but not least I am grateful for the support and encouragement by my
husbandAndorandmydaughtersKiraandKim,bymyparents,mysisterAnnika,
my extended family, and best friends.
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Abrasives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Corundum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1 Chemistry, Types and Characteristics of Corundum . . . . 8
2.1.2 Manufacture of Corundum by Electrofusing . . . . . . . . . 12
2.1.3 Manufacture of Corundum by Sintering . . . . . . . . . . . . 15
2.1.4 Manufacture of Corundum by Sol-Gel Process. . . . . . . . 16
2.1.5 Performance of Corundum . . . . . . . . . . . . . . . . . . . . . 17
2.2 Silicon Carbide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.1 Chemistry, Types and Characteristics of Silicon
Carbide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.2 Manufacture of Silicon Carbide. . . . . . . . . . . . . . . . . . 22
2.2.3 Performance of Silicon Carbide . . . . . . . . . . . . . . . . . . 23
2.3 Diamond. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3.1 Chemistry, Types of Diamond and Performance. . . . . . . 24
2.3.2 Natural Diamond Genesis . . . . . . . . . . . . . . . . . . . . . . 28
2.3.3 Artificial Synthesis of Diamonds . . . . . . . . . . . . . . . . . 29
2.3.4 Performance of Diamonds. . . . . . . . . . . . . . . . . . . . . . 31
2.4 Cubic Boron Nitride. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.1 Chemistry, Types and Characteristics of CBN . . . . . . . . 32
2.4.2 Synthesis of CBN . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4.3 Performance of CBN . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5 Other Types of Abrasives. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5.1 Natural Abrasives. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5.2 Boron Carbide (B C) . . . . . . . . . . . . . . . . . . . . . . . . . 37
4
2.6 Grit Post-Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.6.1 Crushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.6.2 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.6.3 Chemical Processes . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.6.4 Electrostatic Processes . . . . . . . . . . . . . . . . . . . . . . . . 38
ix
x Contents
2.7 Grit Coatings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7.1 Non-metallic Coatings . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7.2 Metallic Coatings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7.3 Purpose of Coatings. . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.8 Grit Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.1 Grit Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8.2 Shape, Morphology . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.8.3 Hardness and Temperature Hardness . . . . . . . . . . . . . . 44
2.8.4 Toughness, Breaking Behavior. . . . . . . . . . . . . . . . . . . 44
2.8.5 Thermal, Electric and Magnetic Properties. . . . . . . . . . . 45
2.8.6 Distribution of Characteristics Within Batch . . . . . . . . . 46
2.9 Methods for Grit Selection and Analysis. . . . . . . . . . . . . . . . . . 46
2.9.1 Grit Size Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.9.2 Grit Shape Selection and Analysis . . . . . . . . . . . . . . . . 50
2.9.3 Toughness and Breaking Behavior Analysis . . . . . . . . . 52
2.9.4 Analysis of Residual Stress via Polarisation
Microscopy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.9.5 Magnetic Susceptibility Selection and Analysis . . . . . . . 53
2.9.6 Other Analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.9.7 Evaluation of Grit Analysis and Sorting Techniques. . . . 54
2.10 Sustainability Dimensions to Abrasive Grits . . . . . . . . . . . . . . . 56
2.10.1 Technological Dimension . . . . . . . . . . . . . . . . . . . . . . 56
2.10.2 Economic Dimension . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.10.3 Environmental Dimension. . . . . . . . . . . . . . . . . . . . . . 58
2.10.4 Social Dimension. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.10.5 Sustainability Model for Abrasive Grits . . . . . . . . . . . . 60
3 Bonding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Resin Bonds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.1.1 Chemistry and Types of Resin Bonds. . . . . . . . . . . . . . 65
3.1.2 Manufacturing of Resin Bonds. . . . . . . . . . . . . . . . . . . 68
3.1.3 Fillers in Resin Bonds . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1.4 Performance of Resin Bonds. . . . . . . . . . . . . . . . . . . . 72
3.2 Vitrified Bonds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.2.1 Chemistry and Types of Vitrified Bonds. . . . . . . . . . . . 73
3.2.2 Manufacturing of Vitrified Bonds. . . . . . . . . . . . . . . . . 74
3.2.3 Performance/Grit Retention. . . . . . . . . . . . . . . . . . . . . 79
3.3 Metallic Multi-layer Bonds . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.3.1 ChemistryandTypesofMetallicBondsforMulti-layer
Abrasive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.3.2 Manufacturing of Metallic Bonds by Infiltration. . . . . . . 81
3.3.3 Manufacturing of Metallic Bonds by Sintering. . . . . . . . 82
3.3.4 Performance of Metallic Multi-layered Bonds . . . . . . . . 83