Abstract
The electroplated cubic boron nitride (CBN) wheel has perfect precision retention and high-temperature grinding performance, which is widely used in the field of grinding difficult-to-cut materials, such as nickel-based superalloy. However, the research on the influence law and mechanism of grinding surface morphology affected by the wear state of small-size grinding wheel is insufficient, which limits the further promotion and application of electroplated CBN wheel in the field of precision grinding of superalloy materials. Based on the in-depth analysis of the structure of FGH96 turbine disk, and combined with the actual processing requirements, the electroplated CBN wheel was designed, and the abrasive grains size selection experiments and CBN wheel wear experiments were then carried out for the powder metallurgy superalloy FGH96 in turn. The influence law of the abrasive grain size of CBN grinding wheel and the wear state of grinding wheel on the surface morphology was investigated, respectively. The obtained results showed that under the given processing parameters, the surface roughness Ra using 400# and 600# electroplated CBN wheels are around 0.66 μm and 0.53 μm during the normal wear state of grinding wheels, respectively, which can meet the requirement of surface quality less than Ra 0.8 μm in engineering application of turbine disk, and prove the feasibility of small-size CBN wheel grinding FGH96. In addition, the failure form of electroplated CBN wheel is mainly the accumulation and adhesion of abrasive debris, and the crushing and shedding of abrasive grain are hard to appear.
Highlights
The turbine disk is the key load-bearing rotating part of aero-engine, which needs to work reliably for a long time under high temperature and pressure
The results show that under the given experimental conditions, the surface roughness Ra can be less than 0.4 μm, and no distorted lattice or elongated grains are formed in the grinding surface/subsurface layer under the given experimental conditions
The accumulation layer the width of about 270 μm completely covers the process, which a blockage phenomenon of with from indicates that the poor surface quality machined by the wheelComprehensive with wear failure analysis is not caused byFigure the abrasive grains, and scratches appear on the surface, indicating that there is an obvious extrusion shedding of abrasive grains but by theby accumulation of abrasive gaps among indicates that or thebreaking poor surface quality machined the wheel with wear debris failureinisthe not caused by the process, which is a blockage phenomenon of cubic boron nitride (CBN) wheel
Summary
The turbine disk is the key load-bearing rotating part of aero-engine, which needs to work reliably for a long time under high temperature and pressure. The results show that under the given experimental conditions, the surface roughness Ra can be less than 0.4 μm, and no distorted lattice or elongated grains are formed in the grinding surface/subsurface layer under the given experimental conditions Most of these researches are limited to the traditional wheel, and in the actual machining process of turbine grooves and small holes, the traditional wheel is not easy to achieve. It is of great significance to study the point grinding of CBN wheel on FGH96 for improving the surface quality of fine parts of the turbine disk and promoting the manufacture of new aero - engines. The wear process of electroplated CBN wheel during the grinding of FGH96 was investigated, which has great application value in the field of precision machining of FGH96 turbine disk
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