Experimental and numerical characterization of abrasive belt wear and debris formation during dry grinding of nickel-based superalloys with diamond abrasive belts

Abstract

Nickel-based superalloys are the constituent materials of critical components of aero engines. Abrasive belt grinding is an effective method for the precision machining of such difficult-to-machine materials. However, the wear of the abrasive belt greatly affects the quality and integrity of the machined surface. In this study, a physical simulator of abrasive belt grinding was used to carry out diamond belt grinding experiments. The wear behavior of abrasive belts and the shape of debris at different temperatures were mainly investigated. In addition, a three-dimensional finite element model of single abrasive grain grinding was established to analyze the formation of debris. The variations of abrasive belt wear and debris morphology with temperature within the experimental temperature range were obtained. There are four types of wear behavior of diamond abrasive belts: grain flattening, grain shed, dependency blockage, and adhesion blockage. The self-sharpening of the abrasive belt plays an important role in improving the quality of the machined surface. The finite element model accurately simulates the shape of debris at different temperatures and the shape of debris changes apparently with temperature. The critical temperature for the formation of good surface quality is obtained. The research results provide guidance for the selection of abrasive belt grinding process parameters.