Abstract
This paper reports the study of grinding characteristics of sintered alumina ceramic and plasma sprayed alumina coatings with respect to grinding forces, specific grinding energy, force ratio and surface integrity at high wheel speed and moderate downfeed. The ground surface of sintered ceramic showed some signatures of plastic deformation along with micro-brittle fracture whereas, in plasma sprayed ceramic coatings, micro-brittle fracture was the predominant mode of material removal under the same grinding condition. This is attributed to the comparable value of critical depth (dc) in ceramics and very low value of dc in ceramic coatings as compared to maximum uncut chip thickness. In sintered alumina, the specific tangential and normal forces are 0.10 and 0.30 N/mm respectively. On the other hand, the forces observed in plasma sprayed alumina coatings were low, and the maximum forces recorded were 0.05 and 0.23 N/mm respectively. SEM images of chips showed micro-brittle fracture as the predominant mode of material removal. Average surface roughness was found to be low in sintered alumina as compared to that in plasma sprayed coatings. Sintered ceramic was free from residual stress whereas in ceramic coatings, tensile residual stresses were observed.
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