Abstract
Manufacturers face challenges when dealing with abrasives that lose roundness, wear excessively, and suffer from pitting of the surface of the grinding wheel that needs rectification using dressing techniques. Nanostructured abrasive grits manufactured by hybrid fusion processes and by sintering/extrusion/printing processes are found to reduce pitting quite significantly. The phenomenon of wheel collapse is increasing and cycle times developed during the grinding of aerospace alloys are much smaller compared to using conventional materials. This paper reviews the phenomenon of wheel collapse induced by pitting and takes a critical look at the production and analysis of hybrid fused and printed/sintered abrasives. A mathematical analysis is carried out of the diffusion of primary and secondary phases due to mechanical and ultrasonic agitation with the aim of producing abrasive grits with improved strength and retention. Current developments in extruded, printed, and sintered grits for use in precision grinding applications are critically reviewed. The paper concludes by explaining how such abrasives are used in practice by industrial manufacturers of high-precision products.
Highlights
Nanostructured abrasive particles bonded to nanostructured bonding bridges have attracted much interest owing to recent advances in the ultra-precision grinding of surfaces
For a given MRR Qw, the power drawn by a nanostructured grinding wheel is a composition of the power required to cut the material, Pc, the friction effects caused by the grinding wheel rubbing the surface, Pf(t), which generates loading of material to the wheel, the threshold power Pth(t = 0) due to dressing and the type of nanostructured grit used in the wheel, and the threshold scitation.org/journal/npe the loss of collections of abrasive grits continues to occur
This paper focuses on how advances in the technology of manufacturing hybrid fused abrasives and engineered ceramic abrasives are being utilized to produce high-premium abrasive grits that are able to process aerospace materials in the ultra-precision grinding regime
Summary
Nanostructured abrasive particles (grits) bonded to nanostructured bonding bridges have attracted much interest owing to recent advances in the ultra-precision grinding of surfaces. Nanostructured abrasive grits and bonds engineered to plow and slide aerospace alloys focus on the optimum interactions 1.2 (t = 0) and 1.3 (t = 0) (Fig. 1) that reduce the threshold power drawn by the grinding wheel at the start of grinding, Pth(t = 0).. Surface pitting of a grinding wheel is caused by simultaneous fracturing of abrasive grit clusters that are thereby lost in an uncontrolled manner. The mechanism was demonstrated through measurements of the surface roughness of the grinding wheel by Bhateja et al., who showed that large portions of abrasive grit are removed from the bond material in accordance with the bond-post fracture normally seen in the tertiary wear. The following subsections describe the importance of melting and solidification and the action of mixing on the diffusion of chemical species at reaction interfaces in abrasive grits
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