On Energy Assessment of Titanium Alloys Belt Grinding Involving Abrasive Wear Effects

Improved energy utilisation,precision,and quality are critical in the current trend of low-carbon green manufactur-ing.In this study,three abrasive belts were prepared at various wear stages and characterised quantitatively.The effects of abrasive belt wear on the specific grinding energy partition were investigated by evaluating robotic belt grinding of titanium plates.A specific grinding energy model based on subdivided tangential forces of cutting and sliding was developed for investigating specific energy and energy utilisation coefficient EUC.The surface mor-phology and Abbott–Firestone curves of the belts were introduced to analyse the experimental findings from the per-spective of the micro cutting behaviour.The specific grinding energy increased with abrasive belt wear,especially when the belt was near the end of its life.Moreover,the belt wear could lead to a predominance change of sliding and chip formation energy.The highest EUC was observed in the middle of the belt life because of its retained sharp cutting edge and uniform distribution of the grit protrusion height.This study provides guidance for balancing the energy consumption and energy utilization efficiency of belt grinding.

Specific grinding energy and surface roughness of nanoparticle jet minimum quantity lubrication in grinding

Nanoparticles with the anti-wear and friction reducing features were applied as cooling lubricant in the grinding fluid. Dry grinding, flood grinding, minimal quantity of lubrication （MQL）, and nanoparticle jet MQL were used in the grinding experiments. The specific grinding energy of dry grinding, flood grinding and MQL were 84, 29.8, 45.5 J/mm3, respectively. The speci- fic grinding energy significantly decreased to 32.7 J/mm3 in nanoparticle MQL. Compared with dry grinding, the surface roughness values of flood grinding, MQL, and nanoparticle jet MQL were sig- nificantly reduced with the surface topography profile values reduced by 11%, 2.5%, and 10%, respectively, and the ten point height of microcosmic unflatness values reduced by 1.5%, 0.5%, and 1.3%, respectively. These results verified the satisfactory lubrication effects of nanoparticle MQL. MoS：, carbon nanotube （CNT）, and ZrO2 nanoparticles were also added in the grinding fluid of nanoparticle jet MQL to analyze their grinding surface lubrication effects. The specific grinding energy of MoS2 nanoparticle was only 32.7 J/mm3, which was 8.22% and 10.39% lower than those of the other two nanoparticles. Moreover, the surface roughness of workpiece was also smaller with MoS2 nanoparticle, which indicated its remarkable lubrication effects. Furthermore, the role of MoS2 particles in the grinding surface lubrication at different nanoparticle volume con- centrations was analyzed. MoS2 volume concentrations of 1%, 2%, and 3% were used. Experimental results revealed that the specific grinding energy and the workpiece surface roughness initially increased and then decreased as MoS2 nanoparticle volume concentration increased. Satisfactory grinding surface lubrication effects were obtained with 2% MoS2 nanoparticle volume concentration.

Grinding performance evaluation of porous composite-bonded CBN wheels for Inconel 718

For high-efficiency grinding of difficult-to-cut materials such as titanium and nickel alloys, a high porosity is expected and also a sufficient mechanical strength to satisfy the function.However, the porosity increase is a disadvantage to the mechanical strength. As a promising pore forming agent, alumina bubbles are firstly induced into the abrasive layer to fabricate porous cubic boron nitride（CBN） wheels. When the wheel porosity reaches 45%, the bending strength is still high up to 50 MPa with modified orderly pore distribution. A porous CBN wheel was fabricated with a total porosity around 30%. The grinding performance of the porous composite-bonded CBN wheel was evaluated in terms of specific force, specific grinding energy, and grinding temperature, which were better than those of the vitrified one under the same grinding conditions. Compared to the vitrified CBN wheel, clear straight cutting grooves and less chip adhesion are observed on the ground surface and there is also no extensive loading on the wheel surface after grinding.

Investigation on induction brazing of profiled cBN wheel for grinding of Ti-6Al-4V

Profiled monolayer cBN wheel was induction brazed for grinding of titanium dovetail slot in this study.Aimed at acquiring a uniform temperature distribution along the profiled surface and reducing the thermal deformation of the brazed wheel,a finite element model was established to investigate the temperature uniformity during induction brazing.A suitable induction coil and the related working parameters were designed and chosen based on the simulation results.Ag-Cu-Ti alloy and cBN grains were applied in the induction brazing experiment.The results showed geometric deformation of the brazed wheel was no more than 0.01 mm and chemical reaction layer were found on the brazed joint interface.Further validation tests were carried out by grinding of Ti-6 Al-4 V alloy.Compared to the electroplated wheel,the brazed wheel showed better performance such as low specific grinding energy and good ground quality in grinding of Ti-6 Al-4 V alloy.Abrasion wear was found to be the main failure mode for the induction brazed wheel,while adhesion and grains pull-out were the main failure mode for the electroplated wheel.