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The inverse relationship between the specific energy and the grit depth of cut is often referred to as the size effect [17][15] The size effect theory attributes the apparent increase in shear stress with a reduced undeformed chip thickness Taniguchi [18] discussed the size effect in cutting and forming and the modified relationship between specific energy and chip thickness that was initially proposed by Backer et al [19] with his version by including tensile test data in the graph as shown in Figure 327 Referring to the figure, the small chip sizes in grinding (of the order of less than 1 m) cause the energy required to remove each unit volume of material to be significantly higher than conventional turning (chip size >50 m) Resisting shearing stress reduces to the order of 500 N/mm2 between the two processes The reason for this behaviour could be explained based on the defect distribution mode in materials When the chip thickness becomes less than about 1 m, the distribution of moveable dislocations (defects) in the metal crystal approaches zero, and the cutting forces have to overcome the very large atomic bonding forces within the crystals to remove the material as a chip Apart from the size effects, Groover [5] provided additional reasons for the specific energy in grinding being much higher than other conventional machining processes First, the individual grits in a grinding wheel possess extremely negative rake angles with an average of 30 and sometimes as low as 60 These very low rake angles result in low values of the shear plane angle and high shear strains, both of which imply higher energy levels while grinding Secondly, due to the random distribution and orientation of grits in the wheel, not all individual grits are engaged in the actual cutting process Some grains do not project far enough into the work piece surface and may end up rubbing, thus consuming energy without removing any material Thirdly, the combination of size effect, negative rake angles and ineffective grain actions cause the grinding process to be very inefficient in terms of energy consumption per volume of material removed.



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Fig 327:

Fig. 14-23.

Shaw s size effect relationship between chip thickness and resisting shear stress of a carbon steel [17] modified by Taniguchi [18] with the addition of tension tests





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Shaw [20] has related the exponential increase in the specific energy in ultra-precision diamond grinding (UPDG) and ultra-precision single-point diamond turning (SPDT) to the undeformed chip thickness as well when the effective depth of cut becomes less than the radius (the size effect) at the tool or grit tip This results in the chip forming model shifting from one involving concentrated shear (depth of cut or undeformed chip thickness is greater than the tool radius) to a micro extrusion mechanism (chip thickness is less than the tool or grit tip) In the micro extrusion mechanism, more energy is needed to bring a large volume of material to the fully plastic state in order for a relatively small amount of material to escape as a chip In other words, the much greater rate of increase in u with a decrease in the undeformed chip thickness in the microextrusion mechanism is primarily due to the relatively large ratio of the volume deformed to the volume removed [21]

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forward the pawl slides up the tooth and, as the tooth passes, it clicks down again. Moving backward, the tooth hits the pawl and prevents further motion. Note that the ratchet wheel is not normally a gear but will have teeth specially designed for easy motion and solid braking. The pawl needs to be pushed down so that it catches solidly in the ratchet. Gravity can serve this purpose in some cases, or the pawl can be held down with a spring or, in the case of Fig. 14-24, a rubber band.

The high value of specific energy during grinding compared to other conventional machining processes is an indication of the large amount of heat generated relative to the amount of material removed The temperature rise during grinding should be considered carefully because it can adversely affect surface properties such as surface damage, burn and heat cracking, can introduce residual stresses and cause distortion by differential thermal expansion/contraction These phenomena can affect workpiece dimensional accuracy The heat generated will also reduce the life of the wheel In Guideline IV [22], it is stated that If you can, grind wet , implying that a coolant be used if possible when grinding to remove heat before it penetrates either into the workpiece or into the wheel rim The surface temperature during grinding is related to process variables by the following expression [1]:

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