FIELD OF THE DISCLOSURE:

The present disclosure generally relates to maintenance of grinding wheels used for abrasive machining. More particularly  the present disclosure relates to a roll form wheel dresser used for knocking worn-out abrasive particles of a grinding wheel while still maintaining concentricity of the grinding wheel.

BACKGROUND:

A grinding wheel is an expendable wheel made from a matrix of coarse  abrasive particles pressed and bonded together to form a solid  circular shape. Each of the coarse  abrasive particles of the grinding wheel acts as a cutting tool for facilitating abrasive machining. More specifically  sharp cutting edges of each of the coarse  abrasive particles on grinding wheel""s surface remove small chips from a work-piece via shear deformation. In order to achieve effective grinding and satisfactory finish on the work-piece  proper selection of the grinding wheel is of primary importance. The small cutting edges of the coarse  abrasive particles on grinding wheel""s surface become dull with regular use of the grinding wheel. In order to achieve a free cut and produce a satisfactory finish on the work-piece  a layer of coarse  abrasive particles with the sharp cutting edges is required to be maintained on the surface of the grinding wheel. For maintaining a layer of coarse  abrasive particles with the sharp cutting edges on the surface of the grinding wheel  dressing of the grinding wheel is required.

Wheel dressing is the process of knocking worn out abrasive particles with dull cutting edges from the grinding wheel""s surface and exposing fresh abrasive particles with sharp cutting edges on the grinding wheel""s surface  while still maintaining the concentricity of the grinding wheel. The wheel dresser includes hard cutting points that fractures the worn out abrasive particles on the grinding wheel’s surface for re-sharpening of the cutting edges of the worn out abrasive particles or completely removes the worn out abrasive particles for exposing fresh abrasive particles that has sharp cutting edges. The wheel dresser further cleans out tiny spaces between the abrasive particles  thereby removing metallic dust and other particles which eventually clog up pores of the wheel face and adversely effects performance of the grinding wheel.

Apart from proper selection of the correct grinding wheel  selection of the proper truing or dressing tool and proper use thereof is also important. More specifically  incorrect dressing causes a satisfactory grinding wheel to act unsatisfactorily. On the other hand use of a good dressing tool can improve life and grinding action of the grinding wheel.

The wheel dresser includes a plurality of hard cutting points disposed on a surface there-of  the hard cutting points of the wheel dresser rub against the grinding wheel to cause dressing of the grinding wheel. The hard cutting points of the wheel dresser functions like cutting tool and like all cutting tools the hard cutting points of the wheel dresser gets dull with regular use of the wheel dresser. The wheel dresser  particularly  the roll form wheel dresser has a cylindrical body provided with a cavity extending around a periphery thereof. The cavity is having a contour such that the cavity receives a peripheral portion of a grinding wheel of a particular size. As the roll type wheel dresser rotates about an axis of rotation  the cutting points disposed on the curved profile of the cavity rub against the peripheral portion of the grinding wheel to cause dressing of the grinding wheel. Although  the wheel dresser disclosed herein is used for dressing the grinding wheel used in the machining of outer track-surface of the bearings  the wheel dresser of the present disclosure may be used for dressing of grinding wheels used in other applications.

The wheel dresser is required to be appropriately positioned with respect to the grinding wheel being dressed by the wheel dresser for achieving high-grade dressing of the grinding wheel. In accordance with the prior art system for locating the wheel dresser with respect to the grinding wheel  the work-piece and the grinding wheel performing abrasive machining on the work-piece are centrally aligned with respect to each other  whereas top edge of the grinding wheel is considered as a reference for positioning the wheel dresser with respect to the grinding wheel. However  considering the top edge of the grinding wheel as reference for positioning the wheel dresser with respect to the grinding wheel requires lot of time for setting the position of the wheel dresser with respect to the grinding wheel. Considering top edge of the grinding wheel as a reference for positioning the wheel dresser with respect to the grinding wheel leads to inaccurate dressing of the grinding wheel. Inaccurate dressing of the grinding wheel causes inefficient operation of the grinding wheel.

Due to inaccurate dressing of the grinding wheel  the grinding wheel may get permanently damaged and the grinding action thereof may be adversely affected  which in turn may damage the work-piece. Furthermore  if the wheel dresser is not properly placed relative to the grinding wheel  the wheel dresser may also get damaged. The in-appropriate placement of the wheel dresser with respect to the grinding wheel may damage the grinding wheel and the wheel dresser and render the work-pieces machined by the grinding wheel defective.

Accordingly  there is a need for maintaining a large inventory of the wheel dressers and grinding wheels  depending on width of the object and Portion of contour with respect to reference face. Costs associated with maintaining such large inventories of wheel dressers and grinding wheels are also high. There is felt a need to accurately position the wheel dresser with respect to the grinding wheel for preventing damage to the wheel dresser and the grinding wheel  thereby reducing the consumption of the grinding wheels and accordingly reducing the inventory of wheel dressers and grinding wheels. There is a need for reducing part change time & cost associated to it for grinding wheels of Different type/size of bearings. Further  there is a need to reduce consumption of grinding wheels by elimination of initial truing amount.

OBJECTS:

Some of the objects of the present disclosure which at-least one embodiment is able to satisfy  are described herein below:

It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.

An object of the present disclosure is to provide a system for accurately placing a roll form dressing tool with respect to a top edge of a grinding wheel for precision dressing of the grinding wheel.

Still another object of the present disclosure is to provide a system for accurately placing a roll form dressing tool with respect to grinding wheel that reduces the dresser alignment time from 20 minutes to 0 minutes.

Another object of the present disclosure is a system for accurately placing a roll form dressing tool with respect to a grinding wheel that reduces grinding wheel inventory and consumption.

Still another object of the present disclosure is to provide a system for accurately placing a roll form dressing tool with respect to grinding wheel that reduces grinding wheel change time to 0 minutes from 50 minutes as the same grinding wheel can be used for job up to 20 mm curvature width.

Another object of the present disclosure is to provide a system for accurately placing a roll form dressing tool with respect to grinding wheel that reduces initial grinding wheel truing time to 0 minutes from 10 minutes as same grinding wheel is used for new job.

Yet another object of the present disclosure is to provide a system for accurately placing a roll form dressing tool with respect to grinding wheel that reduces truing amount by 3mm which increases grinding wheel life by approximately by 12000 pieces / setting.
Another object of the present disclosure is to provide a system for facilitating quick setting of position of a roll form dressing tool with respect to a grinding wheel.

Still another object of the present disclosure is to provide a system for placing a roll form dressing tool relative to a grinding wheel that enhances life of the grinding wheel.

Yet another object of the present disclosure is to provide a system for placing a roll form dressing tool relative to a grinding wheel that reduces inventory of the grinding wheel.

Another object of the present disclosure is to provide a system for placing a roll form dressing tool relative to a grinding wheel that reduces consumption of the grinding wheel.

Still another objective of the present disclosure is to provide a system for placing a roll form dressing tool relative to a grinding wheel that maintains grinding wheels in proper working conditions.

SUMMARY:

A system for accurately placing a roll form dressing tool/ roll type wheel dresser for dressing a grinding wheel with respect to the grinding wheel used for surface finishing a profile configured on a work piece is disclosed in accordance with an embodiment of the present disclosure. The system includes the roll form dressing tool disposed with respect to the grinding wheel by considering center of the grinding wheel as a reference and formed by considering a top edge of the grinding wheel as a reference.

A method for accurately placing a roll form dressing tool/ roll type wheel dresser for dressing a grinding wheel with respect to the grinding wheel used for surface finishing a profile configured on a work piece is disclosed in accordance with an embodiment of the present disclosure. The method includes the steps of arranging the roll form dressing tool/ roll type wheel dresser with respect to the grinding wheel and the work piece such that axis of rotation of the form dressing tool/ roll type wheel dresser is parallel to the axis of rotation of the grinding wheel and the work piece. Thereafter  positioning the roll form dressing tool with respect to the grinding wheel by considering center of the grinding wheel as a reference and finally forming the dressing tool by considering a top edge of the grinding wheel as a reference.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:

The disclosure will now be explained in relation to the accompanying drawing  in which:

Figure 1a illustrates a prior art system for placing a roll form dressing tool with respect to a grinding wheel  wherein top edge of the grinding wheel is considered as a reference for positioning the roll form dressing tool and the dressing tool is formed by considering the center of cavity configured on the dressing tool for receiving curved surface of the grinding wheel to be ground or the center of cavity of the work piece as a reference;
Figure 1b illustrates a schematic representation of a roll form dressing tool formed by considering the center of cavity configured on the dressing tool for receiving curved surface of the grinding wheel to be ground or the center of cavity of the work piece as a reference;

Figure 2a illustrates a prior art roll form wheel dresser of Figure 1a and Figure 1b having a cavity provided at a dressing portion thereof referred to as “X”;

Figure 2b illustrates an enlarged view of the dressing portion “X” of the form wheel dresser of Figure 2a;
Figure 3a illustrates a system for accurately placing a roll form dressing tool with respect to a grinding wheel in accordance with an embodiment of the present disclosure  wherein the center of the grinding wheel is considered as a reference for positioning the roll form dressing tool and the dressing tool is formed by considering a top edge of the grinding wheel as a reference.

Figure 3b illustrates a schematic representation of a roll form dressing tool formed by considering a top edge of the grinding wheel as a reference;

Figure 4a illustrates the roll form wheel dresser of Figure 3a and Figure 3b having a cavity provided at a dressing portion thereof referred to as “X”; and

Figure 4b illustrates an enlarged view of the dressing portion “X” of the form wheel dresser of Figure 4a.

DETAILED DESCRIPTION:

The disclosure will now be described with reference to the accompanying drawings which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly  the examples should not be construed as limiting the scope of the embodiments herein.

Referring to Figure 1a of the accompanying drawings  a prior art system 10 for placing a roll form dressing tool 02 with respect to a grinding wheel 04 is illustrated  wherein top edge of the grinding wheel 04 is considered as a reference for positioning the roll form dressing tool 02. In accordance with the prior art system 10  the work-piece 06 and the grinding wheel 04 performing abrasive machining on the work-piece 06 are centrally aligned with respect to each other  whereas top edge of the grinding wheel 04 is considered as a reference for positioning the wheel dresser 02 with respect to the grinding wheel 04. However  considering the top edge of the grinding wheel 04 as reference for positioning the wheel dresser 02 with respect to the grinding wheel 04 requires lot of time for setting the position of the wheel dresser 02 with respect to the grinding wheel 04. Further  the prior art system 10 for positioning the roll form dressing tool 02 with respect to the grinding wheel 04 for dressing the grinding wheel 04 fails to maintain concentricity of the grinding wheel 04. Different sizes of grinding wheels are required for surface finishing different range of products. Further  the dressing tool 02 is formed by considering the center of cavity configured on the dressing tool for receiving curved surface of the grinding wheel to be ground or the center of cavity of the work piece as a reference. More specifically  point “A” is a reference point for designing of the dressing tool 02. However  considering the center of cavity of the dressing tool 02 as reference for designing the dressing tool 02 is inconvenient and time consuming.

Further  Figure1b illustrates a prior art roll form wheel dresser 102 having a cavity 103 provided at a dressing portion thereof for receiving a peripheral portion of a grinding wheel.

Still further  Figure 2a illustrates a prior art roll form wheel dresser 202 having a cavity 203 provided at a dressing portion thereof  referred to as “X” for receiving a peripheral portion of a grinding wheel to be dressed thereby. Figure 2b illustrates an enlarged view of the dressing portion “X” of the form wheel dresser 202.

Referring to Figure 3a of the accompanying drawings  a system 20 for accurately placing a roll form dressing tool/ roll type wheel dresser 12 with respect to a grinding wheel 14 in accordance with an embodiment of the present disclosure is illustrated  wherein center of the grinding wheel 14 is considered as a reference for positioning the roll form dressing tool 12 and the dressing tool 12 is formed by considering a top edge of the grinding wheel i.e. line “B” as a reference. In accordance with the system 20  the work-piece 16  the grinding wheel 14 performing abrasive machining on the work-piece 16 and the roll form dressing tool 12 are all centrally aligned with respect to each other. Centrally aligning the roll form dressing tool 12 with respect to the grinding wheel 14 is convenient  accurate and requires less time for setting the position of the roll form dressing tool 12 with respect to the grinding wheel 14. The roll form wheel dressing tool 12 has a cylindrical body provided with a cavity 12a extending around a periphery thereof. The cavity is formed with reference of top edge of the grinding wheel 12a is capable of receiving a peripheral portion of the grinding wheel 14. As the roll type wheel dresser 12 rotates about an axis of rotation 18 thereof  the cutting points disposed on the curved profile of the cavity 12a rub against the peripheral portion of the grinding wheel 14 to cause dressing of the grinding wheel 14. The axis of rotation 18 of the roll type wheel dresser 12 is parallel to the axis of rotation of the work-piece 16 and the grinding wheel 14.

Centrally aligning the roll form dressing tool 12 with respect to the grinding wheel 14 reduces the chances of misalignment between the roll form dressing tool 12 and the grinding wheel 14  thereby leading to accurate dressing of the grinding wheel 14 and subsequently enhancing life of the grinding wheel 14 and quality of the surface finish of the work-piece 16. Further  the dressing tool 12 is formed by considering a top edge of the cavity to be ground as a reference. More specifically  “B” is a reference for designing of the dressing tool 12.

TEST SET-UP

Experiments and tests were conducted to determine effectiveness of the system for accurately placing a roll form dressing tool with respect to a top edge of a grinding wheel for precision dressing of the grinding wheel in accordance with an embodiment of the present disclosure. The roll form wheel dresser /roll form dressing tools formed by considering a top edge of the grinding wheel as a reference in accordance with an embodiment of the present disclosure and illustrated in Figures 3a-Figure 4b were used for dressing of grinding wheels of different sizes  shapes and configuration. Similarly  grinding wheels of different sizes  shapes and configuration were dressed by using the prior art roll form wheel dresser formed by considering the center of cavity configured on the dressing tool for receiving curved surface of the grinding wheel to be ground or the center of cavity of the work piece as a reference and illustrated in Figures 1a-Figure 2b. The quality of the dressing attained by using the roll form wheel dresser in accordance with an embodiment of the present disclosure was compared with the quality of dressing attained by using the roll form wheel dresser in accordance with the prior art.

For quantifying quality of the dressing attained by using the roll form wheel dresser in accordance with an embodiment of the present disclosure with respect to the quality of dressing attained by using the roll form wheel dresser in accordance with the prior art  readings of roughness and roundness of the dressed surfaces of the grinding wheels dressed by the roll form wheel dresser in accordance with an embodiment of the present disclosure and roll form wheel dresser in accordance with the prior art respectively were compared. The roughness and roundness of the dressed surfaces of the grinding wheels dressed by the roll form wheel dresser indicative of the quality of the dressing performed by the roll form wheel dresser.

The following tables depicts readings of roughness and roundness of the dressed surfaces of the grinding wheels dressed by the roll form wheel dresser in accordance with an embodiment of the present disclosure and roll form wheel dresser in accordance with the prior art:

Still further  for quantifying dimensional accuracy and effectiveness of the dressing attained by using the roll form wheel dresser in accordance with an embodiment of the present disclosure with respect to the dimensional accuracy and effectiveness of dressing attained by using the roll form wheel dresser in accordance with the prior art  readings of track size  TC out and the degree of wobble experienced during dressing of the grinding wheels dressed by the roll form wheel dresser in accordance with an embodiment of the present disclosure and roll form wheel dresser in accordance with the prior art respectively were compared.

The following tables depicts readings of track size  TC out and the degree of wobble experienced during dressing of the grinding wheels dressed by the roll form wheel dresser in accordance with an embodiment of the present disclosure and roll form wheel dresser in accordance with the prior art respectively.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE:

In accordance with an embodiment of the present disclosure there is provided a system for accurately placing a roll form dressing tool with respect to a grinding wheel for precision dressing of the grinding wheel. The system for accurately placing a roll form dressing tool with respect to a grinding wheel facilitates quick setting of position of the roll form dressing tool with respect to the grinding wheel  more particularly  with the system for accurately placing a roll form dressing tool with respect to a grinding wheel in accordance with the present embodiment  the dresser alignment time is reduced from 20 minutes to 0 minutes. The grinding wheel change time reduced to 0 minutes from 50 minutes as the same grinding wheel can be used for job up to 20 mm curvature width. The initial grinding wheel truing time is reduced to 0 minutes from 10 minutes as same grinding wheel is used for new job. With the roll form dressing tool formed by considering the center of cavity of the work piece as a reference initial grinding wheel truing amount is reduced by 3mm which increases grinding wheel life by approximately by 12000 pieces / setting. Further  no skill is required for aligning the dresser during setting. Further  the system for placing a roll form dressing tool relative to a grinding wheel enhances life of the grinding wheel. Furthermore  the system for placing a roll form dressing tool relative to a grinding wheel reduces consumption of the grinding wheel and accordingly reduces cost of the grinding wheel and consumption per piece of grinding wheel. Furthermore  same grinding wheel can be used for a range of jobs to be ground  thereby reduces requirement of different sized grinding wheels and inventory of grinding wheels.

Throughout this specification the word “comprise”  or variations such as “comprises” or “comprising”  will be understood to imply the inclusion of a stated element  integer or step  or group of elements  integers or steps  but not the exclusion of any other element  integer or step  or group of elements  integers or steps.

The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities  as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

Any discussion of documents  acts  materials  devices  articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

The numerical values mentioned for the various physical parameters  dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters  dimensions or quantities fall within the scope of the disclosure  unless there is a statement in the specification specific to the contrary.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can  by applying current knowledge  readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept  and  therefore  such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore  while the embodiments herein have been described in terms of preferred embodiments  those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

While considerable emphasis has been placed herein on the particular features of this disclosure  it will be appreciated that various modifications can be made  and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein  whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

We Claim:
1. A system for accurately placing a roll form dressing tool/ roll type wheel dresser for dressing a grinding wheel with respect to the grinding wheel used for surface finishing a profile configured on a work piece  said system comprising said roll form dressing tool disposed with respect to said grinding wheel by considering center of said grinding wheel as a reference and formed by considering a top edge of said grinding wheel as a reference.
2. A method for accurately placing a roll form dressing tool/ roll type wheel dresser for dressing a grinding wheel with respect to the grinding wheel used for surface finishing a profile configured on a work piece  said method comprising the steps of:
• arranging said roll form dressing tool/ roll type wheel dresser with respect to said grinding wheel and said work piece such that axis of rotation of said form dressing tool/ roll type wheel dresser is parallel to said axis of rotation of said grinding wheel and said work piece;
• positioning said roll form dressing tool with respect to said grinding wheel by considering center of said grinding wheel as a reference; and
• forming said dressing tool by considering a top edge of the grinding wheel as a reference.