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Grinding performance of AISI D6 steel using CBN wheel vitrified and resinoid bonded

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Abstract

In the last decades, manufacturers attracted much attention to developing processes with competitivity, sustainability, and productivity. One of the most important developments was related to employing more efficient tools. CBN was developed to improve the performance of the abrasive materials by higher hardness, thermal conduction, and chemical stability. In this sense, not only abrasive grains’ properties are important for tool performance, but also bonds are essential for the consolidation of CBN abrasives in manufacturing industry. In order to contribute to findings about the performance of applied bonds in CBN grinding wheels, this work aims to compare CBN grinding wheels composed of vitrified bond and resinoid bond. The workpiece material was AISI D6 special steel which is widely used to manufacture stamping matrix, and this application requires parts with high geometrical and dimensional precision, also high-quality surface finish. For the results analysis and discussion, tangential grinding force and acoustic emission were monitored in order to analyze the process efficiency and surface roughness and G ratio was measured; besides scanning electron, confocal microscopy and optical microscopy were used for the analysis of the ground surface. The vitrified bond provided more efficient results in terms of surface roughness and G ratio in comparison with resinoid bond. However, acoustic emission and tangential grinding force were lower in grinding with CBN resinoid bond what indicated lower mechanical loads. Therefore, this paper presents relevant information to select the appropriate bond to CBN grinding wheel application.

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Acknowledgments

The authors also thank companies Nikkon Ferramentas de Corte Ltda-Saint Gobain Group for providing the grinding wheel and ITW Chemical Products for the donation the cutting fluids, and the authors thank everyone by support to the research and opportunity for scientific and technological development.

Funding

The authors received financial support from São Paulo Research Foundation (FAPESP) (processes, 2015/09197-7, 2015/09868-9, and 2017/03788-9), CAPES (Coordination for the Improvement of Higher Level Education Personnel), and CNPq (National Council for Scientific and Technological Development) for their financial support of this research.

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Authors and Affiliations

  1. Department of Mechanical Engineering, São Paulo State University “Júlio de Mesquita Filho,” Bauru campus, Bauru, São Paulo, Brazil

    Bruno Kenta Sato, Rafael Lemes Rodriguez, Anthony Gaspar Talon, José Claudio Lopes, Hamilton José Mello, Paulo Roberto Aguiar & Eduardo Carlos Bianchi

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  1. Bruno Kenta Sato
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  2. Rafael Lemes Rodriguez
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Correspondence to Bruno Kenta Sato.

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Sato, B.K., Rodriguez, R.L., Talon, A.G. et al. Grinding performance of AISI D6 steel using CBN wheel vitrified and resinoid bonded. Int J Adv Manuf Technol 105, 2167–2182 (2019). https://doi.org/10.1007/s00170-019-04407-5

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