Springer Nature is making SARS-CoV-2 and COVID-19 research free. View research | View latest news | Sign up for updates

Behavior and quantitative characterization of CBN wheel wear in high-speed grinding of nickel-based superalloy

Abstract

This work aims to clarify the wear behavior and quantitatively characterize the wear in cubic boron nitride (CBN) wheels during the high-speed grinding of the nickel alloy, Inconel 718. Grinding experiments were performed first to qualitatively investigate the wear behavior of CBN wheels. To simplify the grinding process, single-grit grinding experiments were carried out to quantitatively characterize the degree of wear on the CBN grain afterwards. The influence of maximum chip thickness on the wear and grinding ratio of CBN grains was studied. Finally, the wear of the CBN wheel was quantitatively characterized by using the wear flat area percentage. It was found that the wear of a single CBN grain increases dramatically at first and then varies little with the increase in the accumulated material removal. The wear flat area percentage of the CBN grinding wheel is able to remain at a low level, and a high and stable grinding ratio can be achieved for CBN wheels. This demonstrates the feasibility of CBN wheels in the high-speed grinding of nickel alloys.

This is a preview of subscription content, log in to check access.

References

  1. 1.

    Caggiano A, Teti R (2013) CBN grinding performance improvement in aircraft engine components manufacture. Procedia CIRP 9:109–114

  2. 2.

    Ichida Y (2008) Mechanical properties and grinding performance of ultrafine-crystalline CBN abrasive grains. Diam Relat Mater 17:1791–1795

  3. 3.

    Varghese B, Kumar K (2003) High removal rate grinding of transmission components using CBN wheels. Proc IMechE B J Eng Manuf 221:1353–1357

  4. 4.

    Guo C, Ranganath S, Mclntosh D, Elfizy A (2008) Virtual high performance grinding with CBN wheels. CIRP Ann Manuf Technol 57:325–328

  5. 5.

    Opitz H, Guhring K (1968) High speed grinding. CIRP Ann 16:61–73

  6. 6.

    Li B, Ni J, Yang J, Liang S (2014) Study on high-speed grinding mechanisms for quality and process efficiency. Int J Adv Manuf Technol 70:813–819

  7. 7.

    Aspinwall D, Soo S, Curtis D, Mantle A (2007) Profiled superabrasive grinding wheels for the machining of a nickel based superalloy. CIRP Ann Manuf Technol 56:335–338

  8. 8.

    Kopac J, Krajnik P (2006) High-performance grinding – A review. J Mater Process Technol 175:278–284

  9. 9.

    Osterle W, Li P (1997) Mechanical and thermal response of a nickel-base superalloy upon grinding with high removal rates. Mater Sci Eng 238:357–366

  10. 10.

    Xu X, Yu Y, Huang H (2003) Mechanisms of abrasive wear in the grinding of titanium (TC4) and nickel (K417) alloys. Wear 255:1421–1426

  11. 11.

    Shi Z, Malkin S (2006) Wear of electroplated CBN grinding wheels. Trans ASME J Manuf Sci Eng 128:110–118

  12. 12.

    Upadhyaya R, Fiecoat J, Malkin S (2007) Factors affecting grinding performance with electroplated CBN wheels. CIRP Ann Manuf Technol 56:339–342

  13. 13.

    Chen Z, Xu J, Ding W, Ma C (2014) Grinding performance evaluation of porous composite-bonded CBN wheels for Inconel 718. Chin J Areo 27:1022–1029

  14. 14.

    Hasuda Y, Handa A, Kobori Y, Kinebuchi S, Furusawa T, Harigaya Y (2012) Grinding of super-alloys using metal-bonded CBN wheel. Key Eng Mater 523–524: 143–148

  15. 15.

    Zhao Z, Fu Y, Xu J, Zhang Z, Liu Z, He J (2016) An investigation on high-efficiency profile grinding of directional solidified nickel-based superalloys DZ125 with electroplated CBN wheel. Int J Adv Manuf Technol 83:1–11

  16. 16.

    Gift F, Misiolek W, Force E (2004) Mechanics of loading for electroplated cubic boron nitride (CBN) wheels during grinding of a nickel based superalloy in water-based lubricating fluids. Trans ASME J Tribol 126:795–801

  17. 17.

    Stetiu G, Lal G (1974) Wear of grinding wheels. Wear 30:229–236

  18. 18.

    Linke B (2015) Review on grinding tool wear with regard to sustainability. Trans ASME J Manuf Sci Eng 137:060801(1)–060801(9)

  19. 19.

    Malkin S, Cook N (1971) The wear of grinding wheels. Part 1-attritious wear. Trans ASME J Eng Ind 93:1120–1128

  20. 20.

    Ding W, Zhu Y, Zhang L, Xu J, Fu Y (2015) Stress characteristics and fracture wear of brazed CBN grains in monolayer grinding wheels. Wear 332–33: 800–809

  21. 21.

    Zhu Y, Ding W, Xu J, Fu Y (2014) Surface fractal evolution of fracture behavior of polycrystalline CBN grains in high-speed grinding. Int J Adv Manuf Technol 76:1505–1513

  22. 22.

    Vickerstaff T (1973) Wheel wear and surface roughness in cross feed surface grinding. Int J Mach Tool Des Res 13:183–198

  23. 23.

    Yoshikawa H, Sata T (1963) Study on wear of grinding wheels. Trans ASME J Eng Ind 85:39–42

  24. 24.

    Jackson M (2004) Fracture dominated wear of sharp abrasive grains and grinding wheels. Proc Inst Mech Eng Part J: J Eng Tribol 218:225–235

  25. 25.

    Ghosh A, Chattopadhyay A (2007) On grit-fracture of an indigenously developed single layer brazed CBN wheel. Ind Diam Rev 1:59–64

  26. 26.

    Fujimoto M, Ichida Y (2008) Micro fracture behavior of cutting edges in grinding using single crystal CBN grains. Diam Relat Mater 17:1759–1763

  27. 27.

    Guo C, Shi Z, Attia H, Mclntosh D (2007) Power and wheel wear for grinding nickel alloy with plated CBN wheels. CIRP Ann 56:343–346

  28. 28.

    Nakai M, Aguiar P, Guillardi H, Bianchi E, Spatti D, D’Addona D (2015) Evaluation of neural models applied to the estimation of tool wear in the grinding of advanced ceramics. Expert Syst Appl 42:7026–7035

  29. 29.

    Hassui A, Diniz A, Oliveira J, Felipe J, Gomes J (1998) Experimental evaluation on grinding wheel wear through vibration and acoustic emission. Wear 217:7–14

  30. 30.

    Hwang T, Whitenton E, Hsu N, Blessing G, Evans C (2000) Acoustic emission monitoring of high speed grinding of silicon nitride. Ultrasonics 38:614–619

  31. 31.

    Malkin S, Guo C (2008) Grinding technology: theory and applications of machining with abrasives, 2nd edn. Industrial Press, New York

  32. 32.

    Ren J, Yang M, Li Y, Wu X (1997) Grinding characteristic of nickel-based superalloy. Acta Aero Astro Sin 18:755–758

Download references

Author information

Correspondence to Yucan Fu.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Zhao, Z., Fu, Y., Xu, J. et al. Behavior and quantitative characterization of CBN wheel wear in high-speed grinding of nickel-based superalloy. Int J Adv Manuf Technol 87, 3545–3555 (2016). https://doi.org/10.1007/s00170-016-8686-1

Download citation

Keywords

  • High-speed grinding
  • CBN
  • Wear behavior
  • Quantitative characterization
  • Grinding ratio