Abstract
Cubic boron nitride (cBN), in addition to diamond, is one of the two superabrasives most commonly used for grinding hard materials such as ceramics or difficult-to-cut metal alloys such as nickel-based aeronautical alloys. In the manufacturing process of turbine parts, electroplated cBN wheels are commonly used under creep feed grinding (CFG) conditions for enhancing productivity. This type of wheel is used because of its chemical stability and high thermal conductivity in comparison with diamond, as it maintains its shape longer. However, these wheels only have one abrasive layer, for which wear may lead to vibration and thermal problems. The effect of wear can be partially solved through conditioning the wheel surface. Silicon carbide (SiC) stick conditioning is commonly used in the industry due to its simplicity and good results. Nevertheless, little work has been done on the understanding of this conditioning process for electroplated cBN wheels in terms of wheel topography and later wheel performance during CFG. This work is focused, firstly, on detecting the main wear type and proposing a manner for its measurement and, secondly, on analyzing the effect of the conditioning process in terms of topographical changes and power consumption during grinding before and after conditioning.
Highlights
Aircraft are formed by numerous parts made of a wide variety of materials, depending on their applications
The wheel was observed after five different wear states, namely, a brand new wheel, after being dressed with a silicon carbide (SiC) stick, after grinding 122 cm3, after grinding 5070 cm3, and after grinding 8112 cm3
The surface of the electroplated Cubic boron nitride (cBN) grinding wheels during the creep feed grinding (CFG) of aeronautic components made of C1023 was analyzed at different wear states
Summary
Aircraft are formed by numerous parts made of a wide variety of materials, depending on their applications. The outer structure is mainly made of materials with a good ratio of strength to weight, for example aluminum alloys and composites, while steel and titanium alloys are used as well to a lesser extent as compared to turbines [1] (see Figure 1). The turbine components are made of special titanium alloys and nickel alloys, which are called superalloys [2]. These materials are called high-performance alloys due to their excellent mechanical strength, resistance to thermal creep deformation, good surface stability, and resistance to corrosion. As a consequence of these enhanced properties, the manufacturing processes of the parts made of these materials need to be carried out either under special conditions or with special tools.
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