Simulation of intermittent grinding for Ti-6Al-4V with segmented wheel

Abstract

Abstract Titanium alloy-Ti-6Al-4V, in spite of all its superior mechanical characteristics and functional acceptance, is categorized as a difficult-to-cut super alloy. Major concerns associated with conventional surface grinding of Ti-6Al-4V is its poor thermal conductivity, grinding burn, high tendency of hardening during machining as well as chemical affinity with wheel materials. Higher magnitudes of grinding force and temperature reported during conventional grinding may lead to adverse burning effects and associated concerns such as micro-cracking etc. on the ground surface. Present paper is a simulation study to showcase the capability of intermittent-segmented grinding to eliminate such concerns. A comparison of intermittent segmented cutting with conventional abrasive action in continuous mode is presented through a 3D finite element model in ABAQUS. The effectiveness of intermittent-segmented cutting to control grinding temperature well below the critical limit to avoid burning effects on Ti-6Al-6 V, with a significant reduction in grinding force is illustrated through the present simulation study.