Abrasive machining process characterization on material removal rate, final surface texture, and power consumption for wood

Abrasive machining is one of the most important processes in wood processing industries and therefore merits special attention and study. The objective of this study was to characterize the abrasive machining process to gain a better understanding of the variables that most significantly affect the material removal rate, surface quality, and power consumption. A full factorial experimental design was developed to determine the impact of a combination of interface pressure, wood species, abrasive, and belt speed. The impact and interactions of these parameters on material removal rate, final surface roughness, and power consumption for three different grit sizes were determined. Data analysis established the statistical significance of the variables and their interactions. Results indicate that material removal rate can be changed by modifying pressure level, abrasives (aluminum oxide and silicon carbide in P100, P150, and P220), and machining speed. Power consumption increased linearly when pressure was increased. Yet, power consumption remains fairly steady for the same pressure and speed levels regardless of the type of abrasive or wood species (at the levels tested). Surface roughness values were higher (rougher) for aluminum oxide abrasive for both hard maple (Acer saccharum) and eastern white pine (Pinus strobus). In most cases, a high belt speed produced a better final surface quality than low belt speed. Statistical analysis showed that most of the variables were statistically significant at the levels studied but only a few interactions were. The statistical analysis responses were also consistent with qualitative assessments. © Forest Products Society 2005.