Tool wear behavior of vitrified microcrystalline alumina wheels in creep feed profile grinding of turbine blade root of single crystal nickel-based superalloy

Abstract

Different aspects on the tool wear behavior of profiled vitrified microcrystalline alumina wheels during creep feed grinding of Ni alloy blade root were investigated. Experimental results indicate that the wheel peak regions had the higher wear values than the wheel valley regions by around 21.7%, 42.8%, 34.5%, in terms of the profile heights, circle radii and angles respectively. Furthermore, the wear flats, workpiece material adhesion, and the fractures of grains and bond bridges occurred in the wheel peak regions; while in the wheel valley regions, heavy wheel clogging, fractures of grains, and workpiece material adhesion were produced. Based on the experimental results, an analytical model with the average error of 17.3% to predict the wheel profile wear was finally developed.