Radial Wear Research Articles

Wear behavior of white alumina and seeded gel abrasive wheels in ultrasonic vibration-assisted grinding of nickel-based single-crystal alloy

This study investigated the tool wear behavior of white alumina (WA) and seeded gel (SG) abrasive wheels in the ultrasonic vibration-assisted creep feed grinding (UVACFG) of nickel-based single-crystal alloy. The abrasive wheel wear characteristics were examined, and their effects on the grinding force, temperature, and surface quality were evaluated. Finally, the wheel wear mechanism in the UVACFG was discussed by analyzing the intermittent cutting behavior and wear patterns of a single grain. Experimental results indicated that the workpiece material adhesion and pore-clogging were the main wear patterns of abrasive wheels without ultrasonic vibration. In contrast, these were adequately mitigated after introducing ultrasonic vibration, and the main wear pattern for both wheels became the grain fracture. The WA wheel in the UVACFG experienced reduced radial wear by around 60.7 % in the initial wear state, 40.2 % in the stable wear state, and 25.3 % in the rapid wear stage, respectively, compared to the conventional grinding (CG). The intermittent cutting behavior of SG grains caused by high-frequency vibration promoted the micro-fracture capacity and ensured the coolant entered the grinding zone sufficiently, which reduced the grinding force and temperature by up to 63.2 % and 46.7 %, respectively, and meanwhile introduced the defects of high bulges and slight plastic deformation on the workpiece surface.

Analysis and Enlightenment on the Relationships between Two Kinds of Cutter Life Evaluation Indexes and Installation Radius: A Case Study

Accurate evaluation of cutter life at different cutter positions on the cutter head is helpful to determine the time of cutter change and reduce the time of cutter wear measurement, which is of great significance to improve the tunneling efficiency of tunnel boring machine (TBM) projects. Unfortunately, there is no unified cutter life evaluation index now. The field data of cutter wear are collected from a section of a long TBM tunneling water conveyance tunnel in China. Two kinds of cutter life evaluation indexes (based on the radial wear extent of cutter rings and replacement number of cutter rings) are selected and the variation rule between these two kinds of indexes with cutter installation radius is statistically analyzed. The results show that the regression relationships between the two kinds of cutter life evaluation indexes and installation radius mainly present linear functions and quadratic functions. Those regression relationships are affected by factors such as wear type, installation angle, cutter spacing, influence width, and allowable limit wear extent of cutter rings. Considering the calculation accuracy of the evaluation index, the actual working conditions of the disc cutter, and ignoring the influence of tunnel diameter, it is recommended to preferentially choose the radial wear extent of cutter rings per unit rolling distance as the evaluation index of cutter life. The research results can provide a reference for the selection of cutter life evaluation index, prediction of disc cutter life at different cutter positions, and establishment of cutter life prediction mode.

Preparation and performance study of electroplated Ni–W/diamond ultrathin dicing blades

In this study, Ni–W/diamond ultrathin dicing blades with various tungsten contents were fabricated using a composite electrodeposition technique by adding different concentrations of sodium tungstate to a nickel sulfamate plating solution utilizing a self-developed cathodic autorotating plating apparatus. The results showed that the tungsten content in the dicing blades increased, the deposition rate accelerated, the distribution uniformity of the diamond particles improved, and the mechanical properties were noticeably enhanced with an increase in the sodium tungsten concentration in the plating solution. The performance of the dicing blade reached its peak at a sodium tungstate concentration of 6 g/L. At this point, the diamond content in the Ni–W/diamond dicing blade was higher and more uniformly distributed; the base metal of the dicing blade, a Ni–W alloy, increased in hardness by 47% and in Young's modulus by 26.8% when compared to Ni; the dicing blade's microhardness reached a maximum of 12.4 GPa, an increase of 49.4% over Ni/diamond dicing blades. The average friction coefficient and wear of the dicing blades decreased by 23.4% and 46.5% respectively. The cutting test results also showed that all aspects of the cutting performance of the dicing blade were greatly improved, with the deviation coefficient of Ni–W/diamond dicing blade decreased by 47.9% compared with that of the Ni/diamond dicing blade, the chipping size decreasing by 30.6%, and the radial wear reducing by 31.6%.

Analysis of force and wear mechanism of shield hob under conventional working conditions

In order to study the force and wear of the hob during the excavation of the composite formation, Abaqus simulation is used to simulate the stress state of the hob when breaking the rock and soil. Based on the abrasive wear mechanism, a prediction model of radial wear amount and linear wear rate suitable for a single hob is derived, and verified with actual engineering data. The results show that the normal force plays an important role in the rock breaking of the hob, and the penetration degree and the cutting edge radius are important factors affecting the normal force of the hob. When the penetration degree increases, the normal force and radial wear of the hob will increase, but the increase of radial wear will slow down due to the width of the cutting edge. Working with the “small-large-small” penetration law not only improves the boring efficiency but reduces the loss of the hob. Therefore, the study provided references for the hob wear and optimization research.

Vanadis 4E’nin Kaplamalı Matkaplarla Delinmesinde; Aşınma, Yüzey Pürüzlülüğü ve Talaş Oluşumunun İncelenmesi

Vanadis 4E is a versatile powder metallurgical tool steel widely used in today's market with high wear resistance and excellent yield properties. Drilling operations applied to materials are one of the operations commonly used in the machining industry. In drilling operations, coated or uncoated drills are used, which may vary according to the material used. This study applied drilling operation to Vanadis 4E powder metallurgical steel with TiN-coated HSS drills. In the study, Drills with diameters of 5, 8.5, and 10.5 mm, cutting speeds of 22, 23, and 24 m/min, and feed rates of 0.10, 0.12, and 0.14 mm/tooth was used. Nine experiments were carried out using the Taguchi L9 orthogonal array. After the experiments, the material was cut from the holes, and the roughness values were measured from the inner surfaces of the holes. In addition, hardness measurements were made from the material surfaces around the holes. The wear conditions of the drills used in the experiments were examined with an optical microscope after the experiment. The formations after each experiment were also examined. The best roughness value was obtained with the 5 mm diameter drill in the 1st experiment, the best roughness value was obtained in the experiments carried out with the 8.5 mm diameter drill in the 6th experiment, and the best roughness value was obtained in the 7th experiment for the 10.5 mm diameter drill. When the wear in the drills was evaluated, it was observed that the side surface and radial wear occurred.

ОБОСНОВАНИЕ ТЕХНОЛОГИЙ УПРОЧНЕНИЯ И ВОССТАНОВЛЕНИЯ ДЕТАЛЕЙ РАБОЧИХ ОРГАНОВ СКОРОСТНОГО ПЛУГА ПСКУ

High-speed plows of domestic production have been widely used in recent years. The resource of parts of the working bodies and their durability cannot be considered sufficient, although these indicators are comparable with those for plows imported into the country. The aim of the research was the development of technologies for strengthening and restoring parts of the working bodies of highspeed plows of the PSKu series, based on the geometric shape of wear. Structural elements of the working bodies, both in the state of delivery and decommissioned, became prototypes for the creation of restoration and hardening technologies. Electrodes for various purposes, as well as a composite abrasive-resistant material developed at the Bryansk State Agrarian University, were used as materials. The experimental parts were tested in full-scale conditions when plowing loamy soils. 24 products of each name were monitored. The operating time was 25 hectares per case. As a result of the work performed, it is shown that radial wear is eliminated by welding with electrodes that provide an abrasion-resistant coating. If the residual wear thickness is 2 mm and through-wiping is present, their elimination is carried out by surfacing on pre-installed electrodes or by applying an abrasive-resistant epoxy-sand composite. For hardening, it is necessary to carry out surfacing reinforcement of the surfaces of the most likely occurrence of wear and areas that have been subjected to technological influences during restoration, as well as to carry out a strengthening surfacing of the back of the left and vertical knives.

Sharpening of graded diamond grinding wheels

Grinding the flutes of cemented carbide end mill cutters results in high and uneven radial wear of the grinding wheel. This is a consequence of the varying geometrical contact conditions over the grinding wheel width. Decreased manufacturing accuracy regarding the tool target geometry is the consequence. To compensate for this, the dressing intervals must be shortened. High non-productive times and an additionally reduction of the grinding layer results from this. The higher non-productive times reduce the productivity of the grinding process and, in conjunction with the shorter lifetime of the grinding tool, thus increase the costs per work piece. It has already been shown that load-adapted grinding wheels can reduce uneven radial wear up to 50%. The adaptation of the wear behaviour to non-uniform engagement conditions causes non-uniform radial wear to occur again under uniform engagement conditions. Uniform engagement conditions occur during grinding wheel sharpening. Therefore, the present study investigates the influence of sharpening on the grinding tool topography. For this purpose, sharpening tests are carried out on four differently graded grinding wheels. For comparability, the tests are also carried out on two non-graded grinding wheels. In the present work, the surface parameters are evaluated with regard to their suitability for analysing the sharpening condition of graded grinding wheels. The grain protrusion derived from this is subsequently used for evaluation. For this, a dependency on the grain concentration is proven and the grain protrusions are shown over the grinding wheel widths. From this, sharpening parameters are determined that enable reproducible sharpening of graded grinding wheels.

A new index for cutter life evaluation and ensemble model for prediction of cutter wear

This paper proposed a new index for evaluation of disc cutter life during earth pressure balance (EPB) tunnelling. This new index was defined as the ratio of accumulated cutter radial wear to working time of the shield machine. With this new index, the measured disc cutter wear can be transformed into a time series data. To predict cutter wear with construction process, an ensemble intelligent model integrating one-dimensional convolutional neural network (1D-CNN) and gated recurrent unit (GRU) was developed via incorporating the proposed cutter wear index. A multi-step-forward prediction mode was adopted to train the ensemble model to predict cutter wear in advance. Field data collected from an EPB tunnelling section in Guangzhou-Foshan intercity railway, Guangzhou, China, was used for validation. Results showed that the proposed index and ensemble model can predict wear of a certain cutter with high accuracy. Three other sequential deep networks were employed for comparison to verify the applicability of the proposed index and ensemble model. The proposed index and ensemble model is convenient to be used on site and can predict wear of a certain cutter on cutterhead to help determine which cutter to be replaced during real-time construction.

ИЗНОСЫ ДЕТАЛЕЙ РАБОЧЕГО ОРГАНА СКОРОСТНЫХ ПЛУГОВ ПСКУ

The use of high-speed plows manufactured in the Russian Federation is due to the intensification of field work and the problem of import substitution. The purpose of the research is to study the wear of the structural elements of the working body of the plow of the PSKu series. The parameters for assessing the technical condition of parts taken out of service were changes in linear dimensions (linear wear). The number of controlled parts for each item was 27 units. Plowing was carried out on loamy soils - 25 ha per product. Research has established that the wear geometry of the surfaces of the left knives has a complex configuration, and the maximum wear in width and thickness is not critical, so the part is suitable for further operation. The control of the right knives according to the residual thickness and the amount of wear of the blade showed that they are in working condition, and the wear of the penetrating area has a radial character and is located in two sections. Typical for vertical knives is radial wear that extends to the side. The thinning of the cutting area leads to local through rubbing of the part. The suitability of these knives for further operation and restoration is determined by their permissible residual width and thickness. The limiting wear of vertical knives determines the working state of the working body. Radiation wear is a defining defect for dumps, although it does not reach its limit value in terms of residual thickness. Therefore dumps after an operating time of 25 hectares are suitable for operation. Thus, the controlled parts are suitable for further operation, however, it is necessary to carry out hardening operations.

Dressing of hybrid-bonded graded diamond grinding wheels

For tool grinding, an optimization potential in terms of productivity is available using graded grinding wheels. This is especially the case when grinding flutes in cemented carbide. Due to the properties of the cemented carbide, high radial wear occurs. Depending on the geometry of the flute, the radial wear varies along the engagement width of the grinding tool. The varying radial wear can be compensated by load adapting the grinding tool properties along its engagement width. The adaptation of the wear behaviour to non-uniform engagement conditions results in non-uniform radial wear occurring under uniform engagement conditions. Indeed, this is the case when dressing these grinding tools. Therefore, this publication presents a method that enables the dressing of graded grinding wheels. For this purpose, four differently graded grinding wheels and two non-graded grinding wheels are dressed with SiC-rolls. Different SiC-rolls, as well as dressing parameters, are investigated. The contour accuracy after dressing is analysed using contour profiles in polyurethane. In the presented paper, dressing parameters are proposed which allow reproducible dressing of all grinding wheels used.

Effect of two different sulfide coated steel fiber towards tribo performance – An interface study

The purpose of friction material is to decelerate a vehicle by transforming the kinetic energy of the vehicle into heat, via friction, and dissipating that heat to the surroundings. A lot of heat is generated at the contact plateaus formed by the reinforcing fibers. Therefore, inorder to dissipate the heat, steel fibers were coated with FeS and SnS and accordingly brake pads were made and termed as DBF and DBS. Another brake pad with similar formulation but with a mixture of steel fiber, FeS and SnS was made (designated as DBO) for comparison. All three brake pads were tested in an inertia brake dynamometer with a typical schedule. The speed spread (100/50 Kmph) 0.6g and effectiveness variation of all the pads are fallen in the required range. The fade I of DBO is observed 32.8% lesser whereas for DBS and DBF, it is observed10% and 15.7% more than the standard values, respectively. DBF and DBO have shown 25.4% and 39.6% more wear than DBS, respectively. Further, it is observed a more consistent µ during single braking to identify fade during stops in the second effectiveness test. It is evidenced for the increase in the life of the friction film formed by the sulfide coated fibers in DBS which has increased its wear resistance (Max Δµ = 0.10 for DBS, 0.29 for DBF, and 0.30 for DBO). It is also noticed that the radial wear of all three brake pads was greater than the tangential wear and their ratios are 1.36, 1.40 and 1.55, respectively for DBS, DBF and DBO. Moreover, the optimization has revealed the DBS as best performer friction materials formulation.

Wear assessment of microcrystalline and electrofused aluminum oxide grinding wheels by multi-sensor monitoring technique

Combining the manufacturing processes with a sophisticated monitoring system is becoming more frequent in industry, following the trend in ‘smart manufacturing’. Multi-sensor monitoring techniques can enhance the efficiency and precision of the manufacturing process. Although many studies have been focused on the grinding process, we are still a long way from a complete understanding, which represents a challenge to the scientific community. The aim of this research was investigate the wear behavior of microcrystalline aluminum oxide grinding wheels, in comparison with a conventional electrofused aluminum oxide grinding wheel, through acoustic emission (AE) monitoring and the use of force transducers. The difference between the two cases is that in the manufacture of microcrystalline aluminum oxide grinding wheels microcrystalline abrasive grains are added to the composition (representing 45 %). A specific experimental rig was assembled for the measurement of the grinding cutting force and AE during the external cylindrical plunge grinding process. Two specific material removal rates were selected for the grinding of nodular cast iron GGG70 workpieces. The experimental rig allows the radial grinding wheel wear to be determined employing an AE-based contact recognition procedure. The wear behavior of the grinding wheel is evaluated by correlating the ground workpiece surface roughness measurements with the post-process analysis of both the grinding force components and AE signals. The results show that the wear behavior of the grinding wheels was dependent on the specific material removal rate used and was characterized by micro and macro-wear mechanisms. It was found through the surface roughness measurements and process characteristics that the addition of microcrystalline aluminum oxide grains has a significant influence on the wear behavior of the grinding wheel. Specifically, the microcrystalline grinding wheel presented lower magnitudes of radial wear when compared to the electrofused grinding wheel. The proposed monitoring method can be widely used to evaluate the wear of grinding wheels during the grinding process.

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.

Analysis of the grinding wheel wear and machining result during cutting edge preparation with elastic bonded grinding wheels

Cutting edge preparation can be considered as one of the most effective methods for optimizing the cutting tool life and the machining result. In this article, a preparation technique using elastic bonded superabrasive grinding wheels is applied. This method proved to be highly flexible in terms of the achievable cutting edge geometry. However, very little knowledge exists about the grinding wheel wear behavior and therefore the process reliability during cutting edge preparation. In this article, the impact of the process kinematics and parameters on the grinding wheel wear and preparation result is investigated and discussed. For this purpose, the impact of the depth of cut (20, 40 and 60 μm) was investigated, because it serves as the major setting parameter for the size of the cutting edge rounding. However, it also impacts the contact conditions and thermo-mechanical loads in the grinding wheel. The experimental results show that this preparation method achieves a high preparation accuracy and repeatability at small and medium depths of cut (20 and 40 μm). For a depth of cut of 60 μm, the preparation result became more inappropriate (increased deviation of the cutting edge shape from an ideal radius) with an increasing number of prepared cutting edges. Here, the soft grinding wheel exhibited a higher process stability in terms of repeatable machining results. The machining results correspond to the experimental findings from the grinding wheel radial wear Δrs. At a depth of cut of 20 and 40 μm, the grinding wheel radial wear for the hard bond was lower than for the soft bond. At a depth of cut of 60 μm, the grinding wheel radial wear for the hard bond exceeds the value for the soft bond by 10%. However, the grinding (G) ratios for the hard bond were higher for all investigated depths of cut. The highest difference was observed at a depth of cut of 20 μm. Here, the G ratio for the soft grinding wheel was 7.92 and for the hard one 18.53. Furthermore, an application scenario was introduced using suitable dressing cycles, so that up to 138,000 cutting edges (equals 34,500 indexable inserts) could be prepared with one grinding wheel using this preparation technique in industrial tool manufacturing applications.

The Correlation of Movements in the Technological System during Grinding Precise Holes

The article presents the results of the study of the quality parameters of the precise hole, depending on the size, spatial location and condition of the contacting surfaces, the parameters of the state of the contact zone, during finishing grinding. The correlation between the processing modes and the current parameters of the contact zone during internal grinding is established. Dependencies describe the flow cross-feed for the i-th turn increment of the depth of micro-cutting, compensation of radial material removal previous turn, deterioration of the wheel, the increment of the elastic and thermal strains. At the same time, the depth of micro-cutting and the increment of elastic and temperature deformations affect the values of the radial wear of the tool and the radial removal of the material. The equation of displacement balance is developed for discrete processes of hole processing with abrasive tools, during which the analyzed surface area comes into contact with the abrasive tool periodically.

Study on precision dicing process of SiC wafer with diamond dicing blades

An innovative method for high-speed micro-dicing of SiC has been proposed using two types of diamond dicing blades, a resin-bonded dicing blade and a metal-bonded dicing blade. The experimental research investigated the radial wear of the dicing blade, the maximum spindle current, the surface morphology of the SiC die, the number of chips longer than 10 µm, and the chipped area, which depend on the dicing process parameters such as spindle speed, feed speed, and cutting depth. The chipping fractures in the SiC had obvious brittle fracture characteristics. The performance of the metal-bonded dicing blade was inferior to that of the resin-bonded dicing blade. The cutting depth has the greatest influence on the radial wear of the dicing blade, the maximum spindle current, and the damage to the SiC wafer. The next most important parameter is the feed speed. The parameter with the least influence is the spindle speed. The main factor affecting the dicing quality is blade vibration caused by spindle vibration. The optimal SiC dicing was for a resin-bonded dicing blade with a spindle speed of 20 000 rpm, a feed speed of 4 mm/s, and a cutting depth of 0.1 mm. To improve dicing quality and tool performance, spindle vibrations should be reduced. This approach may enable high-speed dicing of SiC wafers with less dicing damage.

Mechanism study of the electrical discharge ablation milling with a microcutting depth

Tool wear inevitably occurs during electrical discharge milling (ED milling), adversely affecting the form precision of machined features. Specifically, radial tool wear negatively influences copying precision. In this study, electrical discharge ablation milling (EDA milling) with a microcutting depth was investigated to improve the machining precision of discharge milling. In the proposed method, the cutting depth of a single layer was kept at the micron level, which is smaller than the discharge gap, and the electrode was set to a fast feeding rate at a constant speed. The microcutting depth of a single layer made the discharge concentrate at the end of the electrode while avoiding the side. Under this method, radial tool wear is prevented to realize high-precision discharge milling. The discharge state and high-precision mechanism of the proposed method were analyzed. Contrast experiments were conducted to compare conventional electrical discharge milling (ED milling), conventional electrical discharge ablation milling with a large cutting depth (EDA milling with a large cutting depth), and EDA milling with a microcutting depth. Results indicated that when peak current was 30A (pulse duration was 150 μs and pulse interval was 120 μs), the machining efficiency of the proposed method (18.8 mm3/min) was 9.5 times that of ED milling (1.97 mm3/min) and was 62% higher than that of EDA milling with a large cutting depth (11.6 mm3/min). Besides, the surface quality and cross-sectional shape precision of the straight groove were significantly improved compared with EDA milling with a large cutting depth.

Tool wear behavior of alumina abrasive wheels during grinding FGH96 powder metallurgy nickel-based superalloy

The tool wear behavior of microcrystalline alumina (MA) and brown alumina (BA) abrasive wheels were comparatively studied during grinding FGH96 powder metallurgy nickel-based superalloy. The grinding ratio, radial wear and grinding force were quantitatively analyzed. The influences of tool wear on surface morphology were discussed. The results suggest that grinding force and radial wear of MA wheel is lower than that of BA wheel. Serious tool wear occurs on both the MA and BA wheel from grinding ratio which is less than 1.8 because of the material adhesion and pores clogging. Meanwhile, several defects were found on the ground surface.

The influence of the reinforcement of the chisel-shaped area of the ploughshare on the change in the geometric parameters of radial wear during operation

The formation of radial wear is a decisive factor in the removal of shares from service, i.e. this type of wear refers to the characteristics of the limiting state of the part. It is noted that the dynamics of its formation and development in a certain way affects the development of technical processes for the restoration of plowshares. However, the process of wear, in this case, cannot be considered fully studied, therefore the work is devoted to the study of the above issue. Experienced plowshares were used for research: as delivered; with a reinforced chisel-shaped part with elliptical rollers; with a reinforced chisel-shaped part with rollers perpendicular to the field edge; with a reinforced chisel-shaped part, rollers perpendicular to the field cut and surfacing of the buried part for a length of about 100 mm. As a result of experiments, the dependences of the change in the width of radial wear in the function of operating time and changes in the depth of radial wear in the process of plowing were obtained. An explanation of the process of wear during the formation of radial wear is given for all investigated technological options. It was revealed that the change in the geometric parameters of radial wear (width and depth) in the process of origin and development has a single character and is the same for all technological variants of hardening with surfacing reinforcement, while the greatest resistance to the formation of this defect is provided by reinforcement by forming beads perpendicular to the trajectory of soil movement with surfacing the deepening part to a length of 100 mm.

Wear mechanism in high-speed superabrasive grinding of titanium alloy and its effect on surface integrity

Single-layer electroplated cBN wheels offer several advantages over conventional wheels when grinding difficult-to-cut materials, in terms of improved workpiece surface integrity issues, such as lower grinding burn, fewer surface defects, and generation of compressive residual stresses. However, grinding behaviour e.g., grinding forces, temperature, and surface integrity, changes with wheel use while employing single-layer wheels due to progressive wheel wear as dressing is not conducted for them. Therefore, wheel wear and associated grindability studies like grinding forces and surface integrity are essential for the implementation of these wheels in the industry. The present study evaluates the wear mechanism of the electroplated cBN wheel and its effect on the grindability of Ti–6Al–4V. High grinding speeds (40 & 60 m/s) were employed under different cutting fluids environments (water-based soluble oil emulsion in minimum quantity cooling lubrication (MQCL) as well as in flood cooling modes and neat oil in MQCL regime). A lower cutting speed of 20 m/s is also chosen for benchmarking purpose. Grit fracture is found to be the primary mode of wheel wear. An elaborate discussion on the mechanism of cBN grit fracture is presented. It is observed that thermal shock-induced fracture has a dominant effect on wheel wear, and consequently, water-based fluid provided 2–4 times higher radial wear than neat oil up to 40 m/s. Because of lower radial wear, neat oil provided only 0–10% increase in grinding forces, 0–10% decrease in compressive residual stress, and almost the same level of surface redeposition with the progression of cumulative material removal. On the other hand, water-based fluid yielded 30–100% rise in grinding forces, 10–75% decrease in compressive residual stress, and a higher level of surface redeposition.