Abstract
The results of grinding are highly dependent on conditions of workpiece removal process. The material is removed by an unspecified number of abrasive grains of irregular shape and random distribution on the grinding wheel active surface. The interaction between the abrasive grain and the workpiece can be divided into three stages: (i) rubbing, (ii) ploughing and (iii) chip formation. Reciprocal contribution of each stage is dependent on the properties of the workpiece, the grinding parameters, the friction condition between the abrasive grain and the workpiece and the shape of the grains. In the article, the results of numerical and experimental process in the analysis of grinding of Ti-6Al-4V titanium alloy, using a conventional grinding wheel and a newly developed grinding wheel with aggregates of grains, were presented. The analysis of influence of the geometric parameters of the abrasive aggregates and the abrasive grains on the effectiveness of the workpiece removal process is presented. The effects of the geometrical parameters of grains and abrasive aggregates in direction of motion as well as in transversal direction on the size of ridges were determined. It has been observed that increase of the length of sideway material displacement results in the decrease of ridge formation. The results of a numerical analysis were confirmed by experimental research. The analysis of the impact of utilization of abrasive aggregates on the grinding forces, grinding-specific energy and surface roughness was performed. The impact of abrasive aggregates on the decrease of grinding forces and specific energy and the increase of quality of ground surface was observed.
Highlights
Titanium alloys are widely used in the aerospace and biomedical industry [1,2,3]
The intensity of heat generation in the grinding zone depends on the values of grinding forces and is of particular importance in reference to these processing types, in which surface quality without thermal damages is significant [28]
The values of the normal and tangential grinding force referred to the width of grinding zone b are presented in Figs. 9 and 10
Summary
Titanium alloys are widely used in the aerospace and biomedical industry [1,2,3]. The conducted study on the grinding process of Ti-6Al-4V alloy [7, 8] indicates their elevated chemical activity, which may lead to a strong build-up on abrasive grains. Int J Adv Manuf Technol (2018) 94:301–314 indicated high reactivity of titanium alloys with the tools containing diamond and cubic boron nitride Increased adhesion between these elements causes a decrease of a tool life [9]. It is favourable to decrease the rubbing and ploughing in the grinding zone and to ensure stable conditions of the cutting process with abrasive grains. The grinding process of titanium alloys using abrasive tools with aggregates of grains was analysed. Favourable effects of abrasive aggregates resulting from the decreased size of ridges and reduced cross-sections of the layers cut by a single grain were found.
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