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Design of an Original Methodology for the Efficient and Economic Appraisal of Existing and New Technologies in Form Grinding Processes including Helical

Hart, P (2019) Design of an Original Methodology for the Efficient and Economic Appraisal of Existing and New Technologies in Form Grinding Processes including Helical. Masters thesis, Liverpool John Moores University.

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Abstract

The purpose of this research was to create and design a methodology for new product evaluation with an interest in the affects that they could have on form and helical grinding. The design uses a relatively small and commonly available grinding machine so that testing could be done without need for an expensive helical grinding machine typical of that utilised in industry. The contact conditions of the helical grinding process were considered, and the workpiece geometry was designed to closely replicate the form and entry and exit conditions found in helical form grinding of screw compressor rotors. The equipment design allows the grinding forces to be measured in axial, normal and tangential planes. This will allow the variation in axial forces to be explored and allow any variation in hydrodynamic forces to be investigated during the entry and exit regions. Grinding trials showed the importance of the need to measure the true depth of cut for a grinding pass. A novel method of measuring the depth of cut was designed that will allow an accurate measurement of the form position before and after a grinding pass. Replication methods for the workpiece and grinding wheel form were designed to allow capture on the grinding machine to facilitate an economic appraisal method that allows testing to be carried out in a short period of time. A 3D printed coolant nozzle was designed with an air scraper to overcome the air barrier around the periphery of the grinding. The aim of the design was to reduce the need for a high pressure grinding fluid jet and allowing less turbulent flow to enter the grinding nip at lower pressures. A preliminary cost model was created with inputs that relate to form grinding and allow the user to investigate different process parameters and arrive at a cost per part.

Item Type: Thesis (Masters)
Uncontrolled Keywords: grinding; form; helical; cost model
Subjects: T Technology > TA Engineering (General). Civil engineering (General)
Divisions: General Engineering Research Institute
Date Deposited: 21 Jan 2019 10:50
Last Modified: 21 Jan 2019 10:51
DOI or Identification number: 10.24377/LJMU.t.00009983
Supervisors: Morgan, M
URI: http://researchonline.ljmu.ac.uk/id/eprint/9983

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