Abrasive Grinding Wheel Research Articles

Report on Research for the Use and Popularization of Super Abrasive Grinding Wheels

Report on Research for the Use and Popularization of Super Abrasive Grinding Wheels

Thermal management in grinding of superalloys – A critical review

PurposeThis paper is supposed to provide a critical review of current research progress on thermal management in grinding of superalloys, and future directions and challenges. By understanding the current progress and identifying the developing directions, thermal management can be achieved in the grinding of superalloys to significantly improve the grinding quality and efficiency.Design/methodology/approachThe relevant literature is collected from Web of Science, Scopus, CNKI, Google scholar, etc. A total of 185 literature is analyzed, and the findings in the literature are systematically summarized. In this case, the current development and future trends of thermal management in grinding of superalloys can be concluded.FindingsThe recent developments in grinding superalloys, demands, challenges and solutions are analyzed. The theoretical basis of thermal management in grinding, the grinding heat partition analysis, is also summarized. The novel methods and technologies for thermal management are developed and reviewed, i.e. new grinding technologies and parameter optimization, super abrasive grinding wheel technologies, improved lubrication, highly efficient coolant delivery and enhanced heat transfer by passive thermal devices. Finally, the future trends and challenges are identified.Originality/valueSuperalloys have excellent physical and mechanical properties, e.g. high thermal stability, and good high-temperature strength. The superalloys have been broadly applied in the aerospace, energy and automobile industries. Grinding is one of the most important precision machining technologies for superalloy parts. Owing to the mechanical and physical properties of superalloys, during grinding processes, forces are large and a massive heat is generated. Consequently, the improvement of grinding quality and efficiency is limited. It is important to conduct thermal management in the grinding of superalloys to decrease grinding forces and heat generation. The grinding heat is also dissipated in time by enhanced heat transfer methods. Therefore, it is necessary and valuable to holistically review the current situation of thermal management in grinding of superalloys and also provide the development trends and challenges.

Effects of processing parameters and grinding direction on the material removal mechanism of (100) surface single crystal diamond in self-rotating mechanical grinding

The current commonly used method for diamond processing is mechanical polishing using the cast iron grinding wheel (Scaife). However, this method is challenging to meet the processing requirements of semiconductor applications. This study proposes a more efficient grinding method that employs a high-speed self-rotating grinding device, coupled with a bonded abrasive diamond grinding wheel with high self-sharpening properties, to achieve high precision grinding of single crystal diamonds. Different cutting depths, grit sizes, and linear velocities are employed in the processing, and the material removal mechanism is studied through morphology characterization, element content, and other detection methods. The experimental results indicate that the material removal method of diamond (100) crystal surface is influenced by the cutting depth. It is a collaborative removal process in the 〈110〉 and 〈100〉 directions, and the brittle-ductile transition in the <110> direction significantly affects the machining quality. Surface fractures and subsurface cracks primarily occur through cleavage along the (111) plane, so a method to distinguish the orientation of the (100) crystal plane is proposed. Additionally, this study demonstrates the influence of different processing directions on the surface of the diamond within the same plane. By using this method, the surface roughness of the 7 × 7 mm as-grown crystal can be reduced to Ra 0.523 nm within 10 min, with a material removal rate of 32.4 μm/h.

Experimental Investigation of the Calcified Plaque Material Removal Rate in Coronary Rotational Atherectomy

Abstract Rotational atherectomy (RA) is a minimally invasive procedure to remove the calcified atherosclerotic plaque from arteries to restore blood flow. It uses a high-speed, metal-bonded diamond abrasive grinding wheel to pulverize the calcified plaque into absorbable debris via a catheter through the artery. Although RA has been clinically used for over two decades, procedural complications persist and there remains a lack of consensus on the optimal device parameters. This study aims to investigate the material removal rate (MRR) in coronary RA with respect to grinding wheel sizes and rotational speeds based on a tissue-mimicking phantom. Three grinding wheel sizes, 1.25, 1.5, and 1.75 mm in diameter, and three rotational speeds, 1,20,000, 1,50,000, and 1,80,000 rpm, were investigated. The RA MRR was presented as the luminal area gain and measured by microscopy and image processing. The results show the increase in the grinding wheel size or rotational speed leads to a higher MRR and luminal gain in RA. With a 1.75 mm diameter grinding wheel rotating at 1,80,000 rpm in a 2 mm initial diameter lumen, the max MRR and the luminal gain are 2.49 mm2/three passes and 5.09 mm2, respectively. The MRR decreases as the number of grinding passes increases during RA with the same grinding wheel rotating at a constant speed. This study provides a thorough understanding of the wheel size and speed effects on coronary RA MRR for potential improvements in RA devices and clinical operational guidelines.

Evaluating the performance of electrical discharge face grinding on super alloy monel 400

Conventional machining of super alloy Monel 400 is difficult due to its high strength, low heat conductivity, and gummy nature. In this work, the performance of the electrical discharge diamond face grinding (EDDFG) while processing supper alloy Monel 400 is assessed using the super abrasive diamond-coated grinding wheels of three different grit numbers. Preliminary experiments highlighted the superior performance of the EDDFG as compared to that of electrical discharge machining (EDM) and electrical discharge face grinding (EDFG); in terms of material removal rate (MRR), average surface roughness (Ra), and microscopic images of surfaces using scanning electron microscope (SEM). This work aimed to assess the influence of the diamond grit number (DG n ) of the grinding wheel along with other process parameters, viz. grinding wheel speed (GWS), peak current (I p ), and pulse-on-time (T on ) on Ra and MRR. The analysis of variance (ANOVA) confirmed that DG n and GWS significantly affect the response variables. Finally, the multi-objective genetic algorithm (GA) optimization approach was used to determine the optimal parametric settings of the EDDFG process.

The influence of the microrelief of the metal surfaces of the substrate on the adhesive properties of meta-aramid coatings

Purpose. In order improving the tribotechnical properties of the surfaces of parts, a progressive method is the application of a polymer coating on a relatively cheap metal material. When choosing polymers for use in friction nodes, it is important to evaluate their properties, namely strength, heat resistance and wear resistance. In the technological process of applying coatings, the adhesion of polymers is a significant characteristic. The condition of the surface of the substrate and the viscosity of the polymer material should be attributed to the conditions affecting the formation of the adhesive contact. The purpose of this work is a detailed study of the influence of the nature and microrelief of the surface of the substrate on the adhesion ability of meta-aramid itself. The methods. To achieve the goal, a coating was applied to metal plates made of carbon steel St3 and copper alloy M1, the roughness of the surfaces of which was changed with the help of abrasive grinding wheels. The starting material of the coating in the form of a finely dispersed powder was dissolved in dimethylacetamide. A coating with a thickness of 80...100 μm was formed by applying a solution of meta-aramid on the surface of a metal substrate, followed by evaporation of the solvent in a drying cabinet at a temperature of 150...160ОС for 45...50minutes. To determine the strength of the adhesive joint of the meta-aramid coating from the surface roughness of the steel and copper substrate for different concentrations of the polymer solution, mathematical processing, approximation and extrapolation, experimental data were carried out in the work. Findings. The influence of the microrelief of the surface of metal substrates and the viscosity of the polymer solution on the adhesion ability of meta-aramid coatings was investigated. The optimal parameters of the roughness of the substrate and the concentration of the polymer solution were determined using the method of mathematical modeling. The originality. The relationship between adhesion indicators and the roughness of metal surfaces has been established. It helps to form recommendations regarding the parameters of the surface roughness of the substrate to ensure adhesion of the coating. Practical implementation. The application of polymer coating technology allows to increase the performance of parts in friction nodes, using relatively cheap metal materials for their manufacture. The obtained results form recommendations regarding the roughness parameters of the substrate surface and the concentration of the polymer solution.

Experimental investigation of electrochemical cut-off grinding for Inconel-718 and comparative study with Ti-6Al-4V alloy

ABSTRACT In the present study, a hybrid machining process known as an electrochemical cut-off grinding (ECCG) is used for grinding of Inconel-718 material. The specimen (superalloy) contains nickel as major component. It cannot be machined conventionally due to its outstanding properties. During the electrochemical grinding of Inconel 718, the author examines the effects of input voltage (v), tool feed rate (mm/min), electrolytic concentrations (g/ltr), electrolytic flow rate (ltr/min), and grinding speed (rpm) on responses such as material removal rate (MRR) and surface roughness (Ra). The tests contains the bronze-bonded diamond abrasive grinding wheel. The MRR and surface roughness of Inconel 718 and titanium super alloy during the ECCG process are also compared in this research project. Based on the findings of the studies, it appears that the tool feed rate, the flow rate of the electrolyte, and the rotation of the grinding wheel are the maximum influential parameters for enhancing MRR and surface finish during electrochemical cut-off grinding of Inconel 718. Tool feed rates of 0.09 mm/min to 0.18 mm/min, electrolyte flow rates of 5 ltr/min to 8 ltr/min, and grinding wheel speeds of 800 rpm to 2000 rpm are the ideal influencing factors. The comparative analysis demonstrates that Ti-6Al-4 V alloy cannot match Inconel 718’s machinability. Compared to Ti-6Al-4 V alloy, Inconel-718 has an average material removal rate that is up to 1.73 times higher and an average surface quality that is up to 3.16 times better.

Morphology, microstructure evolution and properties of resin-bonded palm kernel and coconut shell grain-based abrasive grinding

This study examined the morphology and microstructural evolution of resin-bonded palm kernel and coconut shell grain-based abrasive grinding wheels and their physico-mechanical and tribological properties. Raw palm kernel shell (PKS) and coconut shell (CNS) samples were obtained, sorted, sun- and oven-dried, pulverised, and screened into fines of 250, 500 and 850 μm grain sizes, and blended at PKS to CNS mixing ratios of 1:0, 0:1, 1:2, 1:1 and 2:1, respectively. The blended grains, on a weight basis of the total aggregates, were bonded with 25 wt.% polyester resin and hardened and catalysed with 1.5 wt.% cobalt compound and methyl-ethyl ketone peroxide. The aggregates were moulded and compressed at a constant pressure of 18 MPa, ejected, and room-cured before being oven-cured to produce the wheels. The microstructural, water absorption, impact, flexural, hardness, and wear rate properties of the produced samples were evaluated. The properties studied were significantly influenced by grain sizes and mixing ratios of the PKS and CNS in the wheels. The least hardness value, 6.42 HRB, and wear rate, 0.44 mg/m were found in wheels produced from aggregates with pure PKS content with 850 and 250 μm grain sizes, respectively. The wheels' durability qualities suggest they could be used as abrasive grinding wheels, in particular, for wood cutting and finishing processes.

Phase transformation and deformation of the high-frequency induction brazed grinding wheel based on multi-field coupling

With the characteristic of the high bonding strength to matrix, good sharpness, and large chip-storage spaces, the brazed super abrasive grinding wheels have superiorities in the machining of difficult-to-machine materials. However, thermal deformation is caused by the high temperature during the brazing process, leading to the accuracy of the brazed grinding wheel being degraded greatly. By means of local heating, high-frequency induction brazing can reduce the thermal deformation of the wheel. Aiming at the thermal deformation mechanism of the induction brazed wheel, a numerical simulation model of thermal-stress-phase multi-field coupling was established considering the temperature-dependent physical properties of the material. The simulation result indicated that the phase transformation occurred near the work surface of the wheel substrate. The depth of phase transformation layer decreased from 6.0 mm to 2.9 mm with the scanning speed increasing from 0.5 mm/s to 2.0 mm/s. The microstructure of the phase transformation layer mainly consisted of ferrite, pearlite, and bainite after brazing. An appropriate scanning speed was more important for the high accuracy of the wheel substrate during the induction brazing, since it had remarkable influence on the stress and deformation than brazing temperature. The experimental results of the microstructure morphology and deformation proved that the numerical simulation model was correct with 10.4% error.

Inert ambiance-assisted laser ablation of CVD diamond leads to enhanced surface quality and grindability

Diamond is a versatile ultimate engineering material that has been recommended for numerous purposes, especially micro mills. Laser-assisted precision grinding is substantiated to be a promising approach for fabricating diamond micro tools. Yet, in practice, the short pulses that render express elimination will deteriorate the flatness of the tool surfaces, bringing about a boost in the risk of edge collapse and a shrink in yield during the subsequent precision grinding. The tactic of ambiance-assisted laser ablation, which introduces an auxiliary gas during the irradiation to promote the ablated domain quality, is proposed in this investigation. Specifically, a raster scanning-based transient temperature distribution simulation is erected to comprehend the ablation mechanism of the chemical vapor deposition (CVD) diamond. Additionally, it can be deduced that the inert nitrogen with high cohesive energy curbs the instantaneous deflagration of oxidation on the Knudsen layer and the activity of dangling bonds that are desorbed at high temperatures. The nitrogen-assisted laser ablation of the diamond sample leads to a maximum dwindling in surface roughness of 33% compared to that with non-ambiance-assisted. Subsequently, the laser-ablated surface optimized by an inert atmosphere is precisely ground with a fine abrasive grinding wheel. The detection of the sharp cutting edge ( r β = 1.74 μm) with almost no notch and the ground flank surface with the roughness of 168 nm indicates that accessing the inert auxiliary atmosphere during ablation can enhance the surface quality of the machined diamond and the corresponding grindability.

Development and Evaluation of Soft Abrasive Grinding Wheel for Silicon Wafer in Wet Mechanical Chemical Grinding

Development and Evaluation of Soft Abrasive Grinding Wheel for Silicon Wafer in Wet Mechanical Chemical Grinding

Finding optimum cutting conditions for augmented grindability of Ti-6Al-4V

ABSTRACT This study is dedicated toward subtractive manufacturing of difficult to process material, Ti-6Al-4 V through an extensively employed precision abrasive machining operation, grinding. Ti-6Al-4 V is the most extensively used material, which needs grinding during its finishing in many cases. However, grinding of the material is challenging due to the characteristics like high chemical reactivity at higher temperature, high hot-hardness, low elastic modulus, and low thermal conductivity. Due to elevated reactivity at raised up temperature, titanium tends to adhere to the abrasive wheel during grinding thus leading to ineffective cutting performance. Its low thermal conductivity intensifies thermal damage to the bonded abrasives forming glazed grits. The present experimental study deals with finding optimum cutting conditions for enhancing grindability of the alloy that involves optimizing the grinding infeed values for different conventional wheels. The optimized dressing infeed is used in the subsequent grinding operation where enhancement of grinding condition is investigated under the application of cutting fluids. The major considerations of the study are identifying coolants and delivery techniques, which follow sustainable developments, and suitable conventional abrasive grinding wheels.

Wear characteristics of brazing diamond abrasive wheel on high efficiency grinding ferrous metals

A kind of diamond abrasive grinding wheel was brazed in high vacuum furnace using Ni–Cr–P–Si active powder filler alloys. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), Raman spectra and X-ray diffraction (XRD) technique analysis were applied to investigate the wear characteristics of brazing abrasive grinding wheel during the process of dry cutting ferrous metal and the interface characteristics of brazing diamond grains to steel substrate. The reaction products such as Cr7C3 and Cr3C2 carbides with columnar shape were formed toward around the diamond brazed interface. The results showed that diamond brazing abrasive wheel had an advantage in terms of more high efficiency and safety than resin grinding wheel during the process on cutting ferrous metals. The main tool wear model was abrasive grains broken, fracture and corrosion which were near the brazed interface. It revealed that the cutting chips were adhered to the surface of broken grains and covered the abrasive grits during the cutting process where arising high temperature on the grinding arc zone. Results proved that the graphitization phenomenon of diamond grits was slightly occurred and the diamond bonding strength was strong enough to meet the requirements of high efficiency and heavy load machining on dry cutting cast iron. The experiment also demonstrated that a kind of safety, high strength and super sharp diamond abrasive wheel could raise machining efficiency on cutting ferrous metal materials.

Texturing Methods of Abrasive Grinding Wheels: A Systematic Review.

Creating textures on abrasive wheels is a strategy that allows a significant improvement in grinding operations. The reduction of the internal stresses in the workpiece and the temperature during the grinding operation generates an increase in the dimensional accuracy of the workpiece and a longer tool life. Textured abrasive wheels can be produced in many different ways. Depending on the processing method, the dimensional accuracy of the tool and its applicability is changed. Some methods can produce tools with three-dimensional grooves; there are also methods that are employed for the re-texturing of grooves after the grooved zone wears out. In the literature, the benefits of textured grinding wheels over traditional wheels have been extensively discussed. However, information on the particularities of texturing methods is still lacking. To clarify the advantages, limitations, and main advances regarding each of the groove production methods, the authors of this article carried out a systematic review. The objective of this work is to establish the factors that are affected by groove production methods and the technological advances in this area. The benefits and drawbacks of various grooving techniques are then reviewed, and potential study areas are indicated.

Wear behavior of a new composite formulation, with TEOS addition, for abrasive vitrified grinding wheels

Vitrified grinding wheels are used in many manufacturing industries to shape and finish metals and other materials in an efficient way. This work addresses a new approach with the use of tetraethyl orthosilicate solution (TEOS solution or silica sol), as an additive, in vitrified abrasive composites for grinding wheels. Different types of composite were produced using always the same materials and processing methods, but with different TEOS contents. Compared with a reference abrasive grinding wheel, the addition of TEOS promoted an improvement in the abrasive tool performance. The new formulation for vitrified abrasive composites showed better dimensional stability during processing (drying and sintering), and could be applied to the production of grinding tools with high dimensional accuracy. With the addition of 3.75 wt% of TEOS there was an increase in the strength of the matrix bonds. The porosity of the composite increased by 7% (from 43.6 to 46.9%), also improving its wear properties, with the quadrupling of the grinding ratio of the abrasive composite. In addition, the surface roughness of the composite decreased (from Ra = 22.9 to 8.4 μm) allowing to improve the surface finish of the workpieces.

Effect of multi-anodes method for enhancing a Ni-D deposition characteristic on super abrasive grinding wheel

Effect of multi-anodes method for enhancing a Ni-D deposition characteristic on super abrasive grinding wheel

Research and Progress on Truing and Sharpening Process of Diamond Abrasive Grinding Tools

With respect to the truing and sharpening of diamond abrasive grinding tools, traditional machining methods are briefly described, and new dressing methods, such as the laser dressing method, are described in detail. It is pointed out that laser dressing of diamond abrasive tools is a green processing method with high efficiency and no environmental pollution. Numerical simulation research on pulse laser dressing of a bronze diamond abrasive grinding wheel was carried out, and a cumulative heat transfer model of laser dressing energy was developed. The temperature evolution law of the bronze bond and diamond abrasive grains dressed by pulsed fiber laser was determined by numerical analysis of the model. An experiment on the laser dressing grinding wheel was carried out; it was found that when the laser power density was 2.52 × 108 W/cm2∼3.36 × 108 W/cm2, the bronze bond materials could be properly removed, and the diamond abrasive grains could be better sharpened. The laser dressing method can achieve the combination of diamond abrasive grinding tool sharpening and truing. The experiment not only demonstrated the correctness and feasibility of the theoretical model but also provided process optimization for research into pulse laser dressing of diamond abrasive grinding tools.

Micro-grooving of brittle materials using textured diamond grinding wheels shaped by an integrated nanosecond laser system

Freeform surfaces including both the aspherical and prismatic concave/convex have been widely utilized in optical, electronical, and biomedical areas. Most recently, it is reported that grinding with structured wheels provides new possibility to generate patterns on hard and brittle materials. This paper reports the latest research progress on micro-grooving glass ceramic using laser structured diamond grinding wheels. A nanosecond pulse laser is firstly integrated into an ultra-precision machine tool and used for the in-line conditioning of super abrasive grinding wheels, i.e., truing, dressing, and profiling/texturing. Meanwhile, an offset compensation method, considering the shifting depth of focus (DoF) at different laser irradiation positions, is proposed to accurately generate various profiles on the periphery of the grinding wheels. Three types of patterns (riblets, grooves, and pillars) are successfully fabricated on the ceramic substrate using the laser textured grinding wheels. The results indicate that the integrated laser system offers high flexibility and accuracy in shaping super abrasive grinding wheels, and the grinding using textured grinding wheels provides a promising solution to generate functional microstructures on hard and brittle materials.

Optimizing the Sharpening Process of Hybrid-Bonded Diamond Grinding Wheels by Means of a Process Model

The grinding wheel topography influences the cutting performance and thus the economic efficiency of a grinding process. In contrary to conventional grinding wheels, super abrasive grinding wheels should undergo an additional sharpening process after the initial profiling process to obtain a suitable microstructure of the grinding wheel. Due to the lack of scientific knowledge, the sharpening process is mostly performed manually in industrial practice. A CNC-controlled sharpening process can not only improve the reproducibility of grinding processes but also decrease the secondary processing time and thereby increase the economic efficiency significantly. To optimize the sharpening process, experimental investigations were carried out to identify the significant sharpening parameters influencing the grinding wheel topography. The sharpening block width lSb, the grain size of the sharpening block dkSb and the area-related material removal in sharpening V’’Sb were identified as the most significant parameters. Additional experiments were performed to further quantify the influence of the significant sharpening parameters. Based on that, a process model was developed to predict the required sharpening parameters for certain target topographies. By using the process model, constant work results and improved process reliability can be obtained.

Novel comparison concept between CBN and Al2O3 grinding process for eco-friendly production

Minimal Quantity of Lubrication was developed to achieve green manufacturing in machining process. In this study, parameters of cutting fluid flow, grinding wheel type and wheel cleaning system were evaluated to achieve the maximum potential of this technique in grinding process. The comparison of super abrasive (CBN) and conventional (Al2O3) grinding wheel, the cutting fluid flow (30 ml/h, 60 ml/h and 120 ml/h), and the wheel cleaning system were analyzed based on: surface roughness, roundness errors, grinding wheel wear, confocal of grounded surface, grinding power, acoustic emission and workpiece microscopy. In a novel way, this study compared the costs per piece and the carbon footprint in terms of CO2 emission for both abrasive tool application. For all the parameters analyzed, the CBN grinding with MQL outperformed the Al2O3 grinding, showing a superior performance not only in terms of surface finishing, on average, 29% lower surface roughness and dimensional deviation 9% lower but also regarding tool efficiencies, such as 127% lower diametrical wear, 42% lower acoustic emission, and 13% lower grinding power. Despite that, the cost per piece was also evaluated for the different lubri-cooling conditions and tools, and the cost per piece recorded for Al2O3 grinding was substantially lower than CBN grinding, irrespective of the lubri-cooling method employed. The cost of grinding for all MQL techniques analyzed with aluminum oxide wheel was, on average, 72% less than grinding with CBN wheel. Besides, the conventional method with the CBN wheel was 7% more expensive than the aluminum oxide wheel.