Silicon Carbide Wheel Research Articles

Evaluating the effect of WCJ with MQL in grinding VP50IM steel with black silicon carbide wheel

Evaluating the effect of WCJ with MQL in grinding VP50IM steel with black silicon carbide wheel

Wheel cleaning jet (WCJ) strategy for green grinding: mitigating greenhouse impact in VP50IM steel machining with green silicon carbide wheel

Wheel cleaning jet (WCJ) strategy for green grinding: mitigating greenhouse impact in VP50IM steel machining with green silicon carbide wheel

Comparative Cutting Fluid Study on Optimum Grinding Parameters of Ti-6Al-4V Alloy Using Flood, Minimum Quantity Lubrication (MQL), and Nanofluid MQL (NMQL)

Titanium alloys have been of paramount interest to the aerospace industry due to their attractive characteristics. However, these alloys are difficult to machine and require grinding post-processes for quality assurance of the products. Conventional grinding takes a long time and uses a flood coolant-lubrication technique, which is not cost effective nor environmentally friendly. Several studies have been performed to prove the viability and benefit of using Minimum Quantity Lubrication (MQL) with vegetable or synthetic-ester fluids. This work aims to find the optimum grinding parameters of creep feed grinding Ti-6Al-4V with a green silicon carbide wheel, using a flood lubrication system with water-soluble synthetic oil, MQL with ester oil, and nano-MQL (NMQL) using alumina-nanopowder homogeneously dispersed within an ester oil. It is concluded that at 0.635 mm and 1.27 mm infeeds, the three lubrication methods performed similarly. At an infeed of 1.905 mm, MQL did not provide desirable quality, though NMQL and flood lubrication performed practically identically. At a cross feed of 0.254 mm, an infeed of 1.27 mm, and a table feed rate of 6.7 m/min, these grinding parameters provide a material removal rate of 2163 mm3/min with a surface roughness across (Ra) of 0.515 µm. These parameters provide the quickest material removal rate while still maintaining industrial quality. This conclusion is based on environmental, economic, and qualitative results.

A comprehensive investigation of surface morphology during grinding of Inconel 625 using conventional grinding wheels

Grinding difficult-to-grind (DTG) materials such as superalloys have shown an upward trend for manufacturing high-precision and durable components. Superalloys, such as Inconel, have superior thermo-mechanical properties that allow them to withstand caustic working conditions and simultaneously make their grindability difficult. In this context, the present work investigates the grinding performance of Inconel 625 (IN 625) using conventional grinding wheels in dry condition. The current investigation uses the alumina wheel and the silicon carbide wheel to keep the cost factor minimum. The outcome of the experiments has been evaluated in terms of grinding forces and surface roughness. Advanced surface characterization techniques such as Scanning electron microscopy, X-ray diffraction, Raman spectroscopy and X-ray photoelectron spectroscopy have been employed to analyze the surface morphology of the ground surfaces produced by both wheels. It has been observed that the alumina wheel has performed much better than the silicon carbide wheel for a higher depth of cut. These observations have also been supported by wheel loading, in which loading for the silicon carbide wheel was approximately four times that of the alumina wheel. Moreover, long and flow types of chips produced by the alumina wheel indicate the better suitability of the alumina wheel while grinding IN 625. The findings of the present work are expected to provide an economical way of grinding IN 625, preferably using an alumina grinding wheel.

Manufacturing process linked to the MQL compared to flood lubrication applied to the grinding of VP50IM steel using black silicon carbide wheel

Manufacturing process linked to the MQL compared to flood lubrication applied to the grinding of VP50IM steel using black silicon carbide wheel

Surface Impregnation of Niobium Alloy in Grinding by Corundum and Silicon-Carbide Wheels

Surface Impregnation of Niobium Alloy in Grinding by Corundum and Silicon-Carbide Wheels

ИЗУЧЕНИЕ ВЛИЯНИЯ СОСТАВА КОМПОЗИТОВ НА ОСНОВЕ СПЕЧЕННОГО ИМПАКТНОГО АЛМАЗА НА ИХ ИЗНОСОСТОЙКОСТЬ ПРИ ОБРАБОТКЕ КАРБИДА КРЕМНИЯ

The article presents the results of comparative tests on the wear resistance of composite materials (CM) sintered at high pressures and temperatures based on impact diamond (diamond-lonsdaleite abrasive — DLA) when processing silicon carbide (SiC). To assess the CM performance based on impact diamonds, a method has been developed for determining the wear resistance, based on the determination of the CM specific productivity. It is shown that for CMs based on impact diamond, it is expedient to use SiC as a binder. For CMs based on impact diamond with an additive of 40 vol.% SiC, specific productivity when machining a silicon carbide wheel is 25–30 % higher than for compositions containing dense BN phases — wBN and cBN. The decrease in the specific productivity of CM “impact diamond — cBN” relative to CM “impact diamond — SiC” is determined by the higher dispersion of crystals of dense BN phases in comparison with SiC, which generally impairs the abrasive ability of the material. In this case, the addition of a coarse fraction of impact diamond 100/63 μm to the charge composition does not lead to an increase in the specific productivity of the abrasive element as compared to CM based on DLA with a particle size of less than 40 μm. Preliminary mechanical activation of the initial charge also reduces the CM abrasive ability due to the formation of a highly dispersed structure of the material.

Impregnation of the surface of niobium alloy when grinding with corundum and silicon carbide wheels

The features of the formation of a relief after grinding a niobium alloy with abrasive tools made of corundum and silicon carbide on a ceramic bond are considered. The treated surface is studied with a scanning two-beam electron microscope. Keywords: niobium, grinding, corundum, silicon carbide, material transfer, impregnation, micro-X-ray pattern. vladim.nosenko2014@yandex.ru

THE INFLUENCE OF THE MEDIUM ON THE INDICATORS OF THE GRINDING OF STEELS AND TITANIUM ALLOYS WITH A TOOL FROM CORUNDUM AND SILICON CARBIDE

When grinding titanium alloys with a silicon carbide wheel, the coolant provides cut-free grinding, a decrease in the performance of the grinding process. The coolant has a significant effect on the ratio of the same components of the cutting force on the counter and passing passes of the table when grinding steels with a corundum wheel and titanium alloys with a silicon carbide wheel.

Study of Metal, Silicon Carbide Crystals and Ceramic Bond Transfer to the Surface of Titanium Alloy during Grinding

The high adhesive activity of titanium alloys in interaction with abrasive materials is the main cause of poor grinding treatment. The most common abrasive material for grinding titanium alloys is silicon carbide. Silicon carbide wheels operate primarily in self-sharpening mode. Wear of the abrasive tool in the self-sharpening mode occurs as a result of brittle destruction of the fret. The purpose of the study was to determine experimentally the crystalline wear products of an abrasive tool, made of silicon carbide, on the treated surface during grinding of a titanium alloy. Samples of VT9 titanium alloy were processed by flat mortise grinding by a wheel of silicon carbide with the use of VOLTES coolant and the characteristic of the abrasive tool - 64CF80L7V. The treated surface was examined on the electron microscope Versa 3D Dual Beam. The condition of the treated surface testifies to the intensive adhesive interaction of the titanium alloy with the abrasive tool. The thickness of the metal deposits reaches 3 microns. As a result of morphological analysis, objects are identified on the treated surface, the appearance of which allows us to attribute them to crystals. The chemical composition of the selected objects was determined by a microprobe analysis in a microscope camera. On the basis of the conducted researches, a presence on the grinded surface of silicon carbide crystals of various sizes and a ceramic ligament is established.

Wear of silicon carbide wheel during grinding of intermetallic titanium aluminide

Wear of silicon carbide wheel during grinding of intermetallic titanium aluminide

Real-time Grinding Wheel Condition Monitoring Using Linear Imaging Sensor

Grinding is a widely used process in precision finishing of machined part surfaces. Grinding wheels, the key component of the grinding process, consist of a mixture of abrasive grains and bonding materials with or without a metal core. During the grinding process, the grits are either removed or broken on the wheel surface due to multiple mechanisms. Such tool wear on grinding wheel determines the quality of the ground surface as well as the part dimension accuracy and machining efficiency. This work presents a new method to monitor the health status of the grinding wheel using linear Charge-coupled Device (CCD) sensor, which captures one-dimensional grayscale images of the grinding wheel surface. The statistical features were extracted from the sensor data to estimate the present tool wear. Compared to general camera imaging method, the proposed approach is able to achieve high speed sampling with the CCD sensor to scan across the width of wheel in milliseconds, which enables the method a potential solution for monitoring the wheel condition in real-time. The method was tested by capturing surface images of a silicon carbide wheel on a commercial grinding machine. Statistical features such as standard deviation, kurtosis, and entropy were extracted from the grayscale color intensity of the image data and compared to the measured wheel life represented by the counted grinding cycles. The statistical features were fused by an Artificial Neural Network (ANN) model to estimate the life of the grinding wheel. Experimental results show a good match between the estimated and true wheel life with an average error less than 5%.

Transfer of Cubic Boron Nitride Grinding Wheel Wear Products to the Nickel Alloy Surface

The article summarizes the results of microscopic and x-ray spectral studies of objects embedded in the surface layer of a nickel alloy after grinding with a wheel of cubic boron nitride (CBN) on a ceramic bond. In the introduction, the authors analyzes the results of research on the use of CBN as an abrasive material. Unlike silicon carbide wheels, CBN tools are a more complex and multi-component structure, which has a significant impact on the self-sharpening of the abrasive tool and the transfer of material. The purpose of this article is to detect and identify the wear products of a CBN grinding wheel on the treated surface of a nickel alloy. As a result of studying the morphology of the alloy surface after grinding with CBN wheels, foreign objects embedded in the metal were detected with a scanning two-beam electron microscope. The chemical composition of the objects was studied by x-ray spectral microanalysis. Based on the obtained spectrograms, the objects were divided into three groups, including peaks of x-ray characteristic radiation: boron and nitrogen characteristic of CBN grains; aluminum and oxygen characteristic of corundum; oxygen, silicon, aluminum, and some elements characteristic of a ceramic bond. Tables of the chemical composition of the studied objects are provided. Conclusions. The transfer of CBN grinding whee wear products from to the treated surface is experimentally proved.

Dressing technology of arc diamond wheel by roll abrading in aspheric parallel grinding

In order to dress arc diamond wheel in aspheric parallel grinding efficiently and precisely, a novel truing technique by roll abrading with silicon carbide wheel was proposed. The rotary axis of diamond wheel and dressing wheel were orthogonal. Based on X/Y/Z three-axis linkage controlling, the diamond wheel moved around the outer cylindrical surface of the dressing wheel. In this process the dressing wheel abraded the surface of arc diamond wheel. After analysis of geometric relationship between diamond wheel and dressing wheel, the mathematical model of motion trajectory during the truing process was established. And the dressing efficiency and accuracy were analyzed theoretically. The width of dressing wheel was a key parameter affecting the precision of diamond wheel and dressing efficiency. Then, experiments of truing a type of resin-bonded arc diamond wheel were carried out. The arc error, radial runout error, and radius fluctuation decreased from about 110 μm, 290 μm, and 10 mm to 4 μm, 1.5 μm, and 0.2 mm respectively by the dressing process within 7 h. And the abrasive grains on the surface of diamond wheel had a better cutting edge. At the end, a large-scale aspheric lens was machined by this diamond wheel. The P-V of form error was below 4 μm. All the experiments verified that this new approach was feasible, and this truing technique had been applied in ultra-precision grinding of large-aperture aspheric lens, which improved the overall processing efficiency.

The Effect of Overlap Ratio and Silicon Carbide Wheel Grinder on Vibration Amplitude and Surface Roughness for Material OCR12VM.

This research aims to find out how big the effect of the overlap ratio and grit size silicon carbide wheel grinder to the vibration amplitude and surface roughness when grinding process and the corelation between the vibration amplitude and surface roughness. This research used the material hardened tool steel OCR12VM. This research using the surface grinding machine KGS818AH model and this research using a variation of process parameters namely 5 variations on the overlap ratio, 4 variations on grit size silicon carbide wheel grinder, 2 variations in the depth of the cut and this research using constant parameters namely constant spindle speed and constant longitudinal feed. The selection the type of abrasive and the selection process parameters (overlap ratio and grit size silicon carbide wheel grinder) can give a great impact on the increased vibration amplitude and surface roughness on material OCR12VM. The conclusion of this study is with increasing overlap ratio, the vibration amplitude and surface roughness will decrease and the finer the grit size silicon carbide wheel grinder, the vibration amplitude and surface roughness will be lower.

Enhancing grindability of Ti–6Al–4V applying ecological fluids under SQL using SiC wheel

Improving grindability of a given material with the application of cutting fluid is a well-established strategy. However, demands from sustainable manufacturing strive for reduction in cutting fluid consumption as well as introduction of unconventional coolants of non-toxic origin to be employed during the operation without sacrificing its performance. Present experimental investigation deals with the analyses of the performances of some unconventional cutting fluids viz. soap water, sodium nitrite and propylene glycol under small quantity lubrication while grinding Ti–6Al–4V using silicon carbide wheel. Relevant parameters to estimate grindability, like grinding force and specific energy requirements, surface roughness, grinding ratio (G ratio), SEM micrographs of ground surface and images of grinding chips are critically analysed and compared with the results obtained using conventional synthetic fluid and dry grinding. Results have revealed that the unconventional grinding fluids perform more satisfactorily. Among all the fluids applied, propylene glycol has provided with much superior grinding results. It has significantly reduced grinding forces, specific energy, surface roughness and improved G ratio while providing superior surface quality.

Wear of Silicon Carbide Wheel During Grinding of Intermetallic Titanium Aluminide

An experimental investigation is reported on the wear of silicon carbide wheel and its influence on the wheel topography and grinding behaviour during the surface grinding of high performance intermetallic gamma titianium aluminide. The radial wear of the wheel was characterised by initial transient state followed by a steady state wear regime and finally a steel rise in wear rate. The initial transient region progressed up to a radial wear of 40 μm. The normal and tangential forces remained approximately constant up to about 25 μm wheel wear and subsequently progressively increased to a maximum at 60 μm wear. The specific energy began approximately at about u = 140 J/mm3 and started progressing beyond radial wear of 25 μm and increased up to 600 J/mm3 at wear of 60 μm. There was high initial roughness value with the fresh wheel with a progressive decrease with continued grinding. There was noticeable increase in roughness value after a radial wear of 60 μm. With the progress of wear there was presence of surface burns, chatter marks and cracking. The presence of blue oxide discoloration was observed during the visual inspection signifying the generation of reasonably high temperature.

Impact of dressing infeed on SiC wheel for grinding Ti-6Al-4V

ABSTRACTPresent experimental investigation is directed toward the optimization of dressing infeed for silicon carbide (SiC) wheel to be employed for grinding difficult-to-machine super alloy Ti-6Al-4V. Grinding wheels are dressed using separate, however, identical 0.75 carat single point diamond dressers at 5, 10, 15, 20 and 25 µm infeed values. Differently dressed wheels are consequently, applied for grinding Ti-6Al-4V under different infeed values of 5, 10 and 15 µm. All the operations have been performed at a constant velocity of 1810 m/min. The performances of the differently dressed SiC wheels are evaluated based on the variations of grinding force components, average surface roughness values, grinding ratio, chip forms and based on the analyses of the micrographs of wheel topologies and also of the ground surfaces, obtained using scanning electron microscope. Following the performance evaluation, the optimized dressing infeed has been found to be 20 µm for the operation range considered herein.

The Effect of the Operating Speed and Wheel Characteristics on the Surface Quality at Creep-Feed Grinding Titanium Alloys

The paper dwells upon flat creep-feed grinding of grooves in Ti6Al4V workpieces. Those were machined with high-porosity silicon carbide wheels of I, H grades at a speed of 20-30 m/s. Machined surfaces were analyzed using a Versa 3D electron microscope. The paper demonstrates the formed morphology of ground surfaces along the workpiece. Higher-speed grinding results in greater concentrations of silicon on the machined titanium alloy surface. Altering the characteristics of the abrasive tool does not have a significant effect on the concentration of silicon on machined surfaces. The paper analyzes how the grade of wheel and the grinding speed affect Ra surface roughness parameter. The article demonstrates the difference in grades of wheels along the surface, at the stage of constant length of arc and the stage of exit.

Grinding of Titanium Using Alumina and Silicon Carbide Wheel

In the ever prospering manufacturing sector, titanium is considered as an important material due to its mechanical properties, but grinding of titanium is quite a challenging task that needs necessary attention in order to improve its grindability. Past research works reported the success of sub-zero degree cooling for enhancing grindability of several materials. The present experimental work explores the effect of application of environment friendly liquid CO 2 during grinding of titanium grade I alloy compared to that under dry condition. Grindability of silicon carbide and alumina wheel is investigated and compared. Experimental results indicate that alumina wheel performs better with liquid CO 2 than SiC wheel and that in dry condition while grinding titanium grade I. Therefore, liquid CO 2 based cooling system may be used in industry with alumina wheel when grinding titanium grade I.