Investigations on processing of cemented carbides and composite materials (BNDCC and DDCC) by means of grinding and hybrid machining

Grzegorz Skrabalak,Andrzej Stwora,Barbara Staniewicz-Brudnik,Elżbieta Bączek

doi:10.17814/mechanik.2015.2.93

Abstract

The paper presents analysis of influence of parameters and conditions of grinding process using diamond grinding wheels with ceramic bond (Ba23 bis, W1) on the geometrical structure and quality of machined cemented carbides (H10S) and composite materials (BNDCC). During performed analyses there was calculated the material removal rate Qw, specific material removal rate Q’w and G coefficient. There was performed comparative analyses of achieved results for various materials. There is also presented influence of machining conditions on the material removal process efficiency and quality of surface after machining of composite materials (DDCC and BNDCC) when using non-conventional machining processes: electrodischarge wire cutting (WEDM), electrochemical machining with rotating tool electrode (RECM) and hybrid process of electrochemical-electrodischarge machining with rotating tool (R-ECDM) with grinding wheel and metal disk as the tool electrode.

Highlights

Modern materials and need for fast and low-loss manufacturing of parts, especially in automotive and aerospace sectors, require cutting tools with high performance characteristics
There is presented influence of machining conditions on the material removal process efficiency and quality of surface after machining of composite materials (DDCC and BNDCC) when using non-conventional machining processes: electrodischarge wire cutting (WEDM), electrochemical machining with rotating tool electrode (RECM) and hybrid process of electrochemical-electrodischarge machining with rotating tool (R-ELECTROCHEMICAL DISCHARGE MACHINING (ECDM)) with grinding wheel and metal disk as the tool electrode
Grinding tests were performed for samples prepared of BNDCC composite materials

Summary

Introduction

Modern materials and need for fast and low-loss manufacturing of parts, especially in automotive and aerospace sectors, require cutting tools with high performance characteristics. Among materials being subject to presented research are composite materials BNDCC (Boron Nitride Dispersed Cemented Carbide), DDCC (Diamond Dispersed Cemented Carbide) and cemented carbides (used as the reference material). Samples of composite materials used for the test purposes were prepared using cubic boron nitride (BNDCC) and diamond (DDCC) grains of size 6–12 μm [1]. In both cases concentration of superhard grains in cemented carbide was 20% (weight of materials before sintering). Cutting tools made of BNDCC and DDCC composite materials are used in the automotive industry for machining of pistons and engine components made of aluminum alloys and cast iron with high cutting speeds and minimum quantity lubrication. Preparing cutting tools of high precision and high quality surface is important

Methods

Results

Conclusion