Abstract
The wear behavior of a single-layer electroplated cubic boron nitride (cBN) grinding wheel was investigated in creep feed grinding Inconel 718 narrow-deep-groove with a width of 2 mm. In this paper, the protrusion height of cBN grits on the side edge of the grinding wheel was measured by three-dimensional optical profiler, and a scanning electron microscope was used to detect the topography of worn cBN grit and the nickel bonding layer. The investigation results indicated that the steady wear stage of the grinding wheel shared more than 84.6% of the wheel life span, and the machining precision of the grinding wheel was kept at a high level. The fracture mode of the cBN grit was proven to be cleavage. The sources of the cleavage cracks were observed on the surface of wear flat or the side surface of the cBN grit. The holding strength of cBN grit could be weakened due to the joint surface breakage, the displacement of grit, or the cracks of the nickel bonding layer. The transition layer was contributed to the decrease of the bonding strength. Severe macro fractures and the concentration of pulled out grits were observed on the transition edge and the inner area of the side edge, separately. This study provides a deep understanding of the wear mechanism of a single-layer electroplated cBN grinding wheel.
Highlights
Nickel superalloys are widely used in the aeronautical engineering field due to their high thermal stability, fatigue resistance, high-temperature strength, and corrosion resistance
The characteristics of the grit height contours were basically consistent with uniform distribution, but the grit height uniformity tended to decrease as the accumulated material removal (AMR) grew in the grinding process
It was clear that the numbers of the grit for the maximum protrusion height tended to decrease with the growth of the AMR
Summary
Nickel superalloys are widely used in the aeronautical engineering field due to their high thermal stability, fatigue resistance, high-temperature strength, and corrosion resistance. Creep feed grinding with a single-layer electroplated cBN grinding wheel is considered to be one of the most suitable technologies for machining a NDG with nickel superalloy. The difficult-to-machine behavior of nickel superalloys coupled with the large rate of the depth-to-width leads to cBN grit wear occurring in the grinding process. During the grinding of Inconel 718 nickel superalloy with an electroplated cBN wheel, the radial wheel wear and the wear modes were evaluated with the advance of the accumulated material removal. Previous studies clarified that the material remove methods of cBN grits varied in different sections of the wheel edge during the profile grinding of an NDG. A single-layer electroplated cBN grinding wheel was employed to machine nickel superalloy NDG in creep feed grinding.
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