Improvement of Abrasive and Edge Cutting Machining Efficiency through Theoretical Analysis of Physical Conditions

This research theoretically illustrates the effect of reducing the angle of entry of the abrasive grain into the work material on energy consumption in grinding operations. This is achieved by changing the shape of the sliding micro- fractures of cutting grains at up grinding and down grinding along the cutting wheel periphery, grinding with a reduced force of friction between the cutting grain and work material, and with the reduced negative rake angle of the cutting grain by using super hard synthetic materials wheels. In edge-cutting machining, they include the application of tangential turning, cut-down milling with an end mill. The ranges of change in the nominal angle of friction between the cutting grain and the work material and the negative rake angle of the cutting grain, under which the energy consumption in machining reaches the lowest values, were determined theoretically. It is shown that the nature of change in the energy consumption in machining is due to a change in the nominal shear angle of the work material. It is established that infinite values of the energy consumption in machining were achieved at a nominal shear angle of the work material equal to the angle of entry of the abrasive grain into the work material. Therefore, it is necessary to increase the nominal angle of shear on the work material by reducing the intensity of friction in the cutting area and the cutting grain negative rake angle. Theoretical determination of the conditions required for increasing the efficiency of machining by increasing the ratio of the tangential cutting force and thrust force, as well as the ratio of the shear thickness to the corner radius of the cutting tool, which reduce the friction in the cutting area and the rake angle of the cutting tool was achieved. It has been demonstrated that it is possible to achieve a reduction in the cutting force while improving the accuracy of grinding machining, by reducing the energy consumption in machining and substantially increasing the speed of the wheel. This predetermines the effectiveness of the use of grinding in finishing operations.