Dressing Mechanism and Evaluations of Grinding Performance with Porous cBN Grinding Wheels

Cubic boron nitride(cBN)grinding wheels play a pivotal role in precision machining,serving as indispensable tools for achieving exceptional surface quality.Ensuring the sharpness of cBN grains and optimizing the grinding wheel’s chip storage capacity are critical factors.This paper presents a study on the metal-bonded segments and single cBN grain samples using the vacuum sintering method.It investigates the impact of blasting parameters-specifically silicon carbide(SiC)abrasive size,blasting distance,and blasting time-on the erosive wear characteristics of both the metal bond and abrasive.The findings indicate that the abrasive size and blasting distance significantly affect the erosive wear performance of the metal bond.Following a comprehensive analysis of the material removal rate of the metal bond and the erosive wear condition of cBN grains,optimal parameters for the working layer are determined:a blasting distance of 60 mm,a blasting time of 15 s,and SiC particle size of 100#.Furthermore,an advanced simulation model investigates the dressing process of abrasive blasting,revealing that the metal bond effectively inhibits crack propagation within cBN abrasive grains,thereby enhancing fracture toughness and impact resistance.Additionally,a comparative analysis is conducted between the grinding performance of porous cBN grinding wheels and vitrified cBN grinding wheels.The results demonstrate that using porous cBN grinding wheels significantly reduces grinding force,temperature,and chip adhesion,thereby enhancing the surface quality of the workpiece.

EXPERIMENTAL RESEARCH ON SLOTTED & PERFORATED ELECTROPLATED CBN GRINDING WHEEL WITH RADIAL JET

A creative conception is proposed to enhance heat transfer in grinding contact zone through jet impinging on the basis of analysis on the mechanism of burn during creep feed grinding, and a new apparatus of slotted & perforated electroplated CBN grinding wheel with radial jet is developed, the effect on heat transfer is studied through the experiment of intermitted creep feed grinding. Experimental results show that the technology of enhancing heat transfer through jet impinging is valid to raise the efficiency of heat transfer in grinding contact zone and it is widely applied to solve the problem in grinding burn for difficult to machine materials.

Characterization and Analysis of Inconel 718 Alloy Ground at Different Speeds

Inconel 718(IN718)alloy is widely applied to fabricate high temperature resistant or corrosion resistant parts due to its excellent mechanical performance.However,the machining of IN718 alloy is difficult as it may cause serious tool wear and poor surface quality(SQ)of the workpiece.In this work,grinding experiments on IN718 alloy at different speeds were conducted by using a CBN grinding wheel.The relationship between grinding speed,SQ and subsurface damage(SSD)was well studied.With increasing grinding speed,surface roughness decreased,and SQ was greatly improved.Meanwhile,the microhardness of the grinding surface declined as the grinding speed increased.The SSD depth was almost unchanged when the grinding speed was lower than 15 m/s,then it decreased with higher grinding speeds.It was attributed to the mechanical-thermal synergistic effect in the grinding process.The results indicated that increasing grinding speed can effectively improve the SQ and reduce the SSD of IN718 alloy.The conclusion in the work may also provide insight into processing other hard-to-machining materials.

Dimension Accuracy and Surface Integrity of Creep Feed Ground Titanium Alloy with Monolayer Brazed CBN Shaped Wheels

Titanium alloy tenon is creep feed ground with monolayer brazed cubic boron nitride （CBN） shaped wheels. The dimension accuracy of the tenon is assessed and the results indicate that it completely meets the requirement of blade tenon of aero-engine. Residual stresses, surface roughness, microstructure and microhardness are measured on ground surfaces of the specimen, which are all compared with that ground with vitrified CBN wheels. Under all the circumstances, compressive residual stress is obtained and the depth of the machining affected zone is found to be less than 40 μm. No phase transformation is observed at depths of up to 100 lain below the surface, though plastic deformation is visible in the process of grain refinement. The residual stress and microhardness of specimens ground with brazed CBN wheels are observed to be lower than those ground with vitrified ones. The arithmetic mean roughness （Ra） values obtained are all below 0.8μm.