Abrasive Layer Research Articles

Durability Investigation of Ultra-Thin Polyurethane Wearing Course for Asphalt Pavement

In this study, a wear-resistant ultra-thin wear layer was fabricated with polyurethane as an adhesive to investigate its durability for pavement applications. Its road performance was investigated based on indoor tests. First, the abrasion test was performed using a tire–pavement dynamic friction analyzer (TDFA), and the surface elevation information of the wear layer was obtained by laser profile scanning. The relationship between the anti-skid properties of the wear layer and the macro-texture was analyzed. Second, a Fourier infrared spectrometer and scanning electron microscope were employed to analyze the evolution of polyurethane aging properties in the pull-out test and accelerated ultraviolet (UV) aging test. The results showed that the mean profile depth (MPD), arithmetic mean wavelength of contour (λa), surface wear index (SBI), stage mass loss rate (σ), and total stage mass loss rate (ω) of the abrasive layer aggregate had significant multivariate quadratic polynomial relationships with the skidding performance of the abrasive layer. The tensile strength of the polyurethane ultra-thin abrasive layer decreased by only 2.59% after 16 days of UV aging, indicating a minimal effect of UV action on the aggregate and structural spalling of the polyurethane abrasive layer.

Enhanced precision lapping techniques for fused quartz optical elements: Synergistic integration of mechanical and mechanochemical processes

Fused silica is a material of great importance in the field of precision optical equipment due to its excellent optical properties, e.g. photolithography, laser fusion devices, etc. However, the material's inherent hardness and brittleness render it a challenging material to process. Therefore, an enhanced precision lapping technique was proposed, i.e., a synergistic integration of mechanical and mechanochemical lapping processes. Firstly, a synergistic lapping tool with an outer layer of porous diamond abrasive and an inner layer of CeO2 abrasive was fabricated by hot press forming method. The reduction of layer thickness due to abrasion and detachment of the porous diamond abrasive layer was analyzed, and the lapping mechanism of porous diamond on fused silica materials was revealed. The surface creation mechanism of the CeO2 abrasive layer on fused silica material was analyzed by molecular dynamics simulation and the results were validated by enhanced precision lapping experiment. The results demonstrated that the surface atoms of fused silica are removed in a ‘remote disordered’ manner by conventional diamond abrasive grains, whereas the surface atoms of fused silica are removed in a ‘proximally ordered’ manner by the fine porous diamond abrasive grains through the micro-multi-flute cutting. Consequently, the grinding of a porous diamond abrasive layer can significantly reduce the processing damage, with the surface roughness of the lapping Ra reaching 199 nm. The lapping of CeO2 induces the formation of an oxygen bridge on the surface of fused silica, which then produces bending vibration. This is followed by the adsorption and diffusion of oxygen atoms, which form the -Ce-O-Si intermediate with the oxygen atoms shared with the fused silica. This process results in the formation of CeSiO3 and CaSiO3 compounds. The final surface quality with a surface roughness of Ra 21 nm was obtained by mechanochemical lapping of the cerium oxide abrasive layer. The single mechanical-mechanochemical composite ultra-precision lapping process provides technical support for the efficient and low-damage processing of hard and brittle components.

Superfinishing with Abrasive Films Featuring Discontinuous Surfaces.

This study introduces innovative designs for abrasive tools aimed at enhancing surface finishing processes. Prototypes consisting of non-continuous abrasive films with discontinuous surface carriers and abrasive layers were developed to improve the efficiency and effectiveness of the smoothing process. Four distinct abrasive films with varying nominal grain sizes were fabricated to explore the versatility and efficacy of the prototypes. The results indicate that the incorporation of carrier irregularities significantly influences surface finishing processes, leading to improvements in material removal efficiency and surface quality. Longitudinal discontinuities facilitate faster removal of irregularities from workpiece materials, reducing the risk of deep scratches on surfaces. Additionally, this study highlights the importance of tool motion patterns in optimizing material removal processes and ensuring surface quality. The integration of carrier irregularities with additional oscillatory tool motion shows promise for further improving surface quality. These findings advance our understanding of abrasive machining processes and provide valuable insights for optimizing abrasive tool designs and machining strategies for enhanced surface finishing.

Эластичные хоны для полирования профилей зубьев термообработанных цилиндрических колес специального назначения

Introduction. The most important component of the technological process of manufacturing of gear wheels of critical products is the operation of teeth honing. Special requirements are imposed on the surface quality of special-purpose gears, where imported abrasive tools were used, the supply of which in modern economic conditions is impossible. Purpose of work: development of formulation, technological equipment and technology of manufacturing of elastic diamond gear hones instead of imported ones for teeth honing of gear wheels of special purpose. Research methods. Subject of research are samples of imported elastic gear hones and created domestic analogs. The mechanical properties, morphology and chemical composition of the abrasive (diamond) layer of the working surface of the teeth and the annular gear were determined. The content of chemical elements was controlled in separate points of the surface and by scanning over the area on a scanning electron microscope. The formulation and technology of production of annular gears were determined. Results and Discussion. Designs of molds for forming the abrasive layer and the hub of the gear hone are developed. The peculiarities of morphology of the material of the working layer and the annular gear of the elastic diamond gear hone are revealed. On the basis of the conducted research, domestic analogs of materials of constituent elements of the gear hone are determined. Two manufacturing technologies were considered: pressing and injection molding. Two molds were made to test the technology: a simplified model consisting of two teeth and a round mold. Several methods of manufacturing hone teeth were analyzed: manufacturing of an abrasive layer with different degree of pre-vulcanization, subsequent introduction of gear material and final vulcanization of the whole product. The mechanical properties of the materials of the working abrasive layer and the annular gear were determined. The chemical composition of the components of the hone and the boundary zone are studied. As a result of the conducted research, recommendations on the formulation of the abrasive layer and the annular gear, technology of manufacturing of the gear hone intended for final treatment of teeth of heat-treated spur wheels of special purpose are given.

A novel 3D printed compliant ball-end grinding tool with crystal structure: Feasibility and performance analysis

During grinding complex components with difficult-to-machine materials, compliance grinding tools often experience shortened life and weakened performance due to intense temperature rise. This paper presents a novel solution strategy of preparing crystal-structured compliance tools using multi jet fusion (MJF), and five structures were selected to evaluates its feasibility and grinding performance. The macro and micro elastic deformation of the tools were analyzed by combining finite element and experiment. The results show that the crystal structure provides similar macroscopic stiffness of the tools and introduces microscopic compliance anisotropy. The crystal structure resulted in a reduction of the grit pull-out ratio by more than 82.60 %, while also alleviating the adhesion of flexible substrates adhesion and the prevention of abrasive layer fall-off, leading to prolonged tool life. Furthermore, compliant grinding tools with a crystal structure achieved comparable material removal capacity, lower surface roughness, and higher energy efficiency. In addition, they used only 29.06 % to 36.22 % of the material consumed in manufacturing. Notably, the material removal rate (MMR) of the star-structure tool can reached 94.72 % of the solid-structure tool. The diamond-structure tool exhibited the lowest ground Ra, accompanied by a reduction in grinding temperature of 19.4 °C.

DETERMINATION OF REGULARITIES OF TREATMENT OF DISKS IN A FLUIDIZED BED OF ABRASIVE

n this work, the main regularities of processing disks in a fluidized bed of abrasive are established.The research was carried out on the АПС-600A installation when processing disks in a fluidized bed of abrasive. When processing discs, abrasive grains of groups 24A, 63C, and a mixture of abrasive grains 24A63+24A20 (50 % + 50 %) were used.The grain size of the abrasive grains varied in the range № 20 … № 80.The processed disks were made of such alloys as VT3-1, VT-9, EI698-VD, steel 45 HRC 38...45, and aluminum alloy D1T. The peripheral speed of the parts is Vp = 5...40 m/s. The maximum air consumption is 2000 Nm 3/h. The pressure of the air that liquefies the abrasive in the air-falling chamber is 5...6 kPa. The disk was immersed in a liquefied layer of abrasive to a depth of 0.2...1.2 of the radius of the disk. The regularities of the dependence of the removal of various materials from the machined surface of the disks on the speed of the part, the grain size, and the brand of the abrasive grain have been established. The dependence of abrasive grain wear on the speed of the part and on its position along the height of the abrasive layer was experimentally established, which allowed forassigning rational modes of processing discs in a fluidized layer of abrasive. The main regularities of the processing of disks in a fluidized bed of abrasive have been established, and the influence of the main parameters of the processing process on the productivity and stability of the abrasive grain has been determined. The main regularities of the process of processing discs in a fluidized bed of abrasive have been established experimentally, which allowsfor determining the main parameters, technological conditions, and modes of the finishing operation of parts manufacturing.

Effects of the Impacting Velocity and Angle on the Grinding Force, Force Ratio and Deformation Behavior During High-shear and Low-pressure Grinding

Background: Background: The normal grinding force is generally larger than the tangential one during conventional grinding processes. Consequently, several machining issues arise, such as a low material removal rate, a high grinding temperature, and poor surface integrity. To overcome the constraints associated with conventional grinding methods, a novel “high-shear and low-pressure” flexible grinding wheel is utilized. A thorough investigation of the influence of machining parameters on the highshear and low-pressure grinding performance from a microscopic perspective is focused. Objective: The effect of the impacting angle and velocity on the grinding force, grinding force ratio, and fiber deformation displacement is explored at the microscopic level. Methods: An impact model was established using ABAQUS software to explore and analyze the interaction results of micro-convex peaks with the abrasive layer under different processing conditions. Results: It was found that the normal grinding force Fn increased with both impact angle and velocity. Similarly, the tangential grinding force Ft is enhanced with increasing velocity. However, its magnitude is reduced with impact angle. Conclusion: The grinding force ratio is primarily affected by the impact angle, which displays a declining trend. The maximum fabric deformation displacement reaches 72.4 nm at an angle of 60° and at a velocity of 9 m/s.

A novel sandwich structured wheel to achieve mirror finish in grinding of a mould steel

A novel manufacturing tool called sandwich flexible elastic grinding wheel is developed to achieve high material removal rates and machined finish of a mould steel. This tool is made of aluminium matrix, ethylene propylene rubber layer and abrasive layer. Ethylene propylene rubber layer has great elasticity and produces elastic deformation when contacting with the workpiece. With the existence of an abrasive layer, rigidity at small scales allows grinding to occur, which can effectively remove the residual height of the surface and improve the surface quality. In this paper, influences of grinding process parameters of the sandwich elastic grinding wheel on the key characterisation parameters of surface integrity are studied, and the surface roughness and material removal rates under various process parameters are investigated. Then, the process parameters that are suitable for mirror machining are selected by experiments and are demonstrated on an S136 mould steel workpiece. Mirror finish can be achieved by single processing. The surface roughness of the mould steel converges from the original Ra142 nm to Ra7.42 nm, the surface texture is more compact and regular, and the surface integrity is significantly improved.

Novel designed mechanical-mechanochemical synergistic micro-grinding technology and compounded abrasive micro-grinding tools

The mechanical and mechanochemical synergistic micro-grinding technology was proposed for grinding hard and brittle materials, especially for fused silica micro parts in this work. Compounded abrasive micro-grinding tools with diamond abrasives on the outer layer and cerium oxide abrasives on the inner layer were designed and fabricated. Efficient grinding was initially achieved by mechanical processing of super hard abrasives, and then ultra-precision processing was obtained by mechanochemical process to remove surface or subsurface damage. This study firstly analyzed the contact model of single diamond abrasive particle and theoretically evaluated ground surface roughness. The mechanism of abrasive layer wear was investigated for accurate error compensation. The formulation of cerium oxide abrasive layer and its processing efficiency were further analyzed. The material removal mechanisms of fused silica during mechanochemical grinding were also studied. Results showed that the material removal rate was 1.924 μm/min and the surface roughness Ra was 0.248 μm after mechanical processing. Subsequently, the surface roughness Ra was improved to 38 nm after mechanochemical processing. The study indicates that this technique is a promising approach for high-efficiency and high-quality grinding of fused silica.

Application of batch manufactured flexible micro-grinding tools on copper and oxidized copper surfaces

As copper is a rather difficult material to machine due to its ductility compared to aluminium, this study presents the approach of oxidizing the surface to improve the results of the grinding process. Therefore, batch manufactured flexible micro-grinding tools are used for grinding of copper and oxidized copper surfaces to machine microstructure or local areas of functional surfaces. Besides, we show a comparison of the performance of an abrasive layer made of silicon carbide (SiC) and cubic boron nitride (cBN). The tools are made of a polyimide-based abrasive layer and silicon as substrate and are fabricated by photolithography and deep reactive ion etching. The oxidation of copper surfaces is done by electrochemical processes and are directly machined with grinding tools. The surface quality is evaluated concerning the surface roughness by optical measurements with confocal microscopy. Lower roughness values are achieved on both, the pure copper and the oxidized copper by using SiC grinding tools. On pure copper this is reflected in a reduction of the arithmetical mean roughness value Ra to 0.04 µm. The unprocessed reference surface shows an Ra of 0.24 µm. In addition, the machined oxidized surfaces show a reduction of the mean roughness depth Rz from 7,60 µm to 1.10 µm, which is an optimization of factor 2 compared to the machined non-oxidized copper surfaces (2.32 µm). The machining of copper with cBN micro-grinding tools also shows improved roughness values, but in comparison to the SiC tools these are 50 % higher for machined copper surfaces and similar for machined oxidized copper surfaces. While the oxidation of the copper surface has a positive effect on the surface quality, no effect on tool wear can be observed.

ОСОБЕННОСТИ ПРОЦЕССА ОБРАБОТКИ СТАТИЧЕСКИ УПЛОТНЕННЫМИ АБРАЗИВНЫМИ СРЕДАМИ ДЕТАЛЕЙ ТИПА ТЕЛ ВРАЩЕНИЯ

The study objective is to find out an analytical dependence that correlates the operating parameters and the conditions of the finishing abrasive treatment with the roughness of the working surfaces of the parts, taking into account the shape factor of the manufactured parts.
 The tasks to which the paper is devoted include theoretical and experimental studies of the effect of the treated surface roughness on the technological modes and conditions of surface treatment of complex-profile parts in the medium of statically compacted loose abrasive, as well as in the development of a methodology for determining rational modes and conditions taking into account the shape factor of the machined parts and determining the achievable range of surface roughness.
 Research methods: theoretical studies are conducted on the basis of the main provisions of mechanical engineering technology, grinding theory, theoretical mechanics, theory of elasticity and plasticity. Experimental studies are carried out according to standard methods in production and laboratory conditions using certified instrumentation. The data obtained are processed using computer technology and presented in the form of empirical dependencies, convenient for practical use.
 The novelty of the work is in finding mathematical dependencies for calculating the pressure of a statically compacted abrasive layer on the surface of the parts being machined, taking into account the shape factor.
 Conclusions: Based on the calculated theoretical dependencies and experimental studies, it is shown that the work of micro-cutting with the microrelief of abrasive grains is approximately 1.5...2 times higher than the work of micro-cutting with the tops of abrasive grains of the grinding wheel. This allows to conclude that the machining of parts with a statically compacted loose abrasive, compared with grinding with a conventional grinding wheel, is a less energy-consuming process of removing material from the surfaces of the machined parts.
 The paper presents peculiarities of finishing parts with statically compacted abrasive media. The ratio of friction work and micro-cutting of the machining is shown. The nature of the contact interaction of abrasive grains with the treated surface is considered for the first time, taking into account the shape factor, and the rational range of final roughness is defined.
 The role of cutting elements of particles affecting the quality and productivity of machining is determined.

Fatigue Performance of Steel Slag SMC Ultrathin Abrasive Layer Under Strain Controlling Mode

Recently, the warm mixing modified ultrathin abrasive layer has been paid great attention due to the green energy-saving strength. In regard to its durability, the study of the fatigue behavior of the SMC warm mixing modified ultrathin abrasive layer asphalt mixture was carried out under the strain controlling mode. The relationship among all characteristic parameters (bending stiffness modulus, normalized times, and products phase angle) and stress cycle times showed a similar three-stage change process, except for the accumulative dissipated energy. The transition point (Nf) between the second (RDEC2) and the third stage (RDEC3) was assumed to be the characteristic fatigue cracking sign for the SMC warm mixing modified ultrathin abrasive layer. In that case, supported by multiobjective system, the relative change of dissipation energy, rather than the 50% initial stiffness, was regarded as the appropriate fatigue cracking criteria.

Producing Processes of the Trace Fossil Asteriacites lumbricalis Revisited: Different Ophiuroid Behaviors Produce Different Trace Forms

The star-shaped trace fossil Asteriacites lumbricalis is produced by ophiuroids and has two different forms. One form has four distinct arms with transverse fine and parallel striations and one indistinct arm without striations, and the producing process has been studied already. In this study, we clarified the producing process of another form with five distinct radiating arms and fine striations by aquarium observations of extant ophiuroids. The form was produced when ophiuroids were covered with a thin sand layer (11–39% of the arm length in thickness). After covered by thin sand, ophiuroids raised their five arms with one to five tips protruded vertically above the sand cover, raised and slanted the disc in the sand, and then obliquely emerged onto the sand cover. Finally, they returned to horizontal postures creeping on the sand. The trace left on the substratum was very similar in shape to the trace fossil from Hettangian (Lower Jurassic) in Blumenrod, Germany. The producing process of the repetitive multiple traces of A. lumbricalis was revealed by aquarium observations. When an ophiuroid was alternately covered with a thin sand layer and then with a thin abrasive layer as mud substratum, the ophiuroid left a vertically stacked series of traces which gradually shifted the horizontal position. This unique form of A. lumbricalis was produced by escaping of ophiuroids from successive deposition events.

Tribological properties of layered silicate nanoparticle filled acrylonitrile butadiene styrene (ABS) nanocomposite produced using 3D printing

ABSTRACT Tribological properties of layered silicate nanoparticle-filled acrylonitrile butadiene styrene (ABS) nanocomposite have been investigated. The nanocomposite spur gear was developed by infusing different weight percentages of nanoclay (0–2 wt.%) on each printed ABS layer using an additive manufacturing 3D procedure. A square panel of 12 layers with varying weight percentages of nanoclay was created using a 3D printer. The effect of nanoclay loading and different sliding distances (122.5 m, 800 m, and 2000 m) on the wear and friction properties conducted at parallel and transverse layer orientation of nanocomposite were investigated. The results show that the loading nanoclay improved tribological properties of 3D printed ABS nanocomposite and spur gear with 2 wt.% nanoclay offered a low wear rate and adequate coefficient of friction irrespective of the abrasion layer orientation. SEM images showed a uniform homogeneous dispersion of nanoclay strongly bonded with the matrix, which produced an interlocking layered structural formation resulting in less wear rate and a stable coefficient of friction. These tribological properties suggested materials that may be positively used for gear applications.

Fabrication and grinding performance of CVD diamond abrasive tool

The chemical vapor deposition (CVD) method has become a new choice for the fabrication of diamond grinding tools with excellent wear resistance. Different diamond abrasive particles were deposited on the lapping and sandblasting pretreated silicon nitride ceramic substrate by hot filament chemical vapor deposition (HFCVD) method to fabricate CVD diamond abrasive tools. To analyze the influence of pretreatment methods on adhesion strength, the micromorphology, surface roughness, Raman stress, and Rockwell indentation of CVD diamond abrasive tools with different parameters were characterized. Meanwhile, grinding tests on cemented carbide wire drawing dies were carried out, and the grinding performance of different abrasive particles was evaluated. The results show that sandblasting pretreatment can increase the matrix surface roughness, accelerate the growth of diamond abrasive particles and improve the adhesion between the abrasive layer and substrate, and the CVD diamond grinding tool with sandblasting pretreatment substrate and coarse particle has the best dust removal ability and the longest grinding life. The cemented carbide grinding tests of the CVD diamond grinding tool and electroplated diamond grinding tool with the same particle size are processed and compared, it shows that the grinding life of the CVD diamond grinding tool is longer, and the surface roughness value of the workpiece is lower than that of the electroplated diamond grinding tool.

Efficient and precision dressing of arc-shaped diamond grinding wheel by laser dressing and electrical discharge dressing

Affected by the characteristics of laser Gaussian beam, the spot size and laser energy irradiated on the grinding wheel surface change at any time with the dressing path, which makes it difficult to realize the dressing of high-precision arc-shaped diamond grinding wheel. In order to achieve high-efficiency and precise dressing of arc-shaped diamond grinding wheels, a composite dressing method using laser rough dressing and electrical discharge precision dressing was first proposed. Laser rough dressing method is used to quickly remove the excess abrasive layer to obtain an arc-shaped profile. Electrical discharge precision dressing not only improved the accuracy of arc-shaped contour, but also realized the grinding wheel sharpening. The optimization of kinematic parameters on the dressing profile accuracy in laser dressing and electrical discharge dressing was explored. An arc-shaped profile with a radius of 13 mm was tested on a diamond grinding wheel with a grain size of 120#. The radius of the final dressed arc-shaped profile is 13,007 μm, and the PV value of the profile error is 10.67 μm. It was found that the abrasive grains on the surface of the grinding wheel were slightly graphitized. The damage degree of the abrasive particles in laser dressing was more serious than that of in electrical discharge dressing. Most of the graphite layer on the surface of abrasive particles could be removed by grinding alumina ceramics. The fitting radius of the arc profile of the workpiece is 13.013 mm, and the profile error PV value is 11.91 μm.

Operational behaviour of graded diamond grinding wheels for end mill cutter machining

The varying related material removal rate during deep grinding of cemented carbide end mill cutters results in an unevenly wear of the grinding wheel. This study therefore presents a simulation-based model for the load-adjusted design of grinding wheels to achieve balanced radial wear, as well as an evaluation of this model. The related material removal rate along the width of the grinding wheel is determined by a Dexel based material removal simulation for different end mill geometries. Based on these results an equation is derived to adapt the abrasive layer properties to the local load differences. Three grinding wheels with different types of gradients are then manufactured by a grinding tool manufacturer based on this equation. These and two grinding wheels with constant abrasive layer properties are used for deep grinding of ten end mills each. Afterwards the radial wear of each grinding wheel is measured by a confocal microscope. An analysis of the cutting edge chipping is done to evaluate the influence on the graded grinding wheels on the cutting edge quality. It was found that a reduction of the wear difference over the grinding wheel width of 52% and an improved cutting edge quality can be achieved by using graded grinding tools. This allows the time intervals between dressing steps to be increased without compromising the accuracy of the grinding process, thus also increasing its productivity. Finally, this article shows that the presented model allows for a more balanced wear behaviour, but has to be extended by considering further factors influencing radial wear.

Wear-adaptive optimization of in-process conditioning parameters during face plunge grinding of PcBN

Polycrystalline cubic boron nitride is a very hard material. Machining of this material is performed by grinding with diamond tools. Due to its high hardness, grinding tools are subjected to severe microscopic and macroscopic tool wear. This wear leads to short tool life and results in high effort in conditioning the abrasive layer. Contrary to the usual conditioning of diamond grinding wheels with diamond dressing tools, this study investigates a conditioning process based entirely on the use of white corundum cup rolls. These conditioning tools allow the in-process face plunge conditioning of vitrified bond diamond grinding tools. The circumferential speed of the conditioning tool and the average grain diameter of the corundum are identified as the main factors influencing the topography of the generated grinding layer. To describe the performance of the conditioning process, a specific conditioning removal rate Q_{sd}^{prime } is derived. This parameter represents a cumulated variable that allows a comparison of different conditioning strategies. It is shown that an increase in Q_{sd}^{prime } significantly counteracts microscopic wear on the abrasive layer. Therefore, optimized process parameters enable the process of in-process conditioning to significantly reduce wear on the grinding tool without increasing the process time or the non-productive time.

Fabrication and use of Cu-Cr-diamond composites for the application in deep feed grinding of tungsten carbide

Machining of tungsten carbide requires the use of highly wear resistant grinding tools, like metal bonded grinding tools. The abrasive layer of these grinding tools can be regarded as Metal-Matrix-Composites reinforced with diamond particles. Copper-Matrix-Composites already are being used as heat sink materials through their outstanding high thermal conductivity. In this work, Cu/Diamond composites with 50 vol% diamond have been fabricated through field assisted sintering and the application of these composites as grinding layers in a deep feed grinding process of tungsten carbide was investigated. Through addition of chromium powder as a carbide former on the surface of the diamond particles, the critical bond strength and therefore the diamond grain retention was significantly increased by +363%. The addition of 2 wt% chromium to the copper matrix also resulted in a +84% increase of thermal conductivity relatively to the chromium free Cu/Diamond composite. Grinding of tungsten carbide as a dynamic stress test showed that the increased grain retention and thermal conductivity resulted in a decrease in grinding layer wear. Further chromium addition to 8 wt% chromium resulted in a decrease in thermal conductivity and the formation of adhesive cloggings on the grinding wheel surface during grinding.

On the grinding performance of metal-bonded aggregated cBN grinding wheels based on open-pore structures

Metal-bonded aggregated cubic boron nitride (cBN) grinding wheels were developed by employing open-pore structures in abrasive layers, aiming to solve the problems, such as severe tool wear, low machining efficiency, and poor quality stability with conventional abrasive grinding wheels. Comparative grinding performances, including grinding forces and force ratio, grinding temperature, specific grinding energy, ground surface roughness were performed between vitrified monocrystalline cBN wheels and porous aggregated cBN wheels. Characterisation of morphologies, such as pore structures and tool wear features were also conducted. Results show that the as-sintered porous aggregated cBN wheels possess the lower grinding forces (reduced by 35.9%–43.3% for Fn′; 3.9%–18.8% for Ft′), a smaller grinding temperature (decreased by 10.4%–71.8%), and a stable grinding force ratio of 2.5 in comparison of vitrified monocrystalline cBN wheels. In addition, the ground surface roughness of porous aggregated cBN wheels ranges from 0.76 to 1.19 μm, whilst the other one possesses over 1.65 μm. Furthermore, the worse ground surface quality is obtained, resulting from the smaller chip storage space and poor self-sharpening ability of vitrified monocrystalline cBN wheels compare to porous aggregated cBN wheels.