Grinding performance evaluation of porous composite-bonded CBN wheels for Inconel 718

For high-efficiency grinding of difficult-to-cut materials such as titanium and nickel alloys, a high porosity is expected and also a sufficient mechanical strength to satisfy the function.However, the porosity increase is a disadvantage to the mechanical strength. As a promising pore forming agent, alumina bubbles are firstly induced into the abrasive layer to fabricate porous cubic boron nitride（CBN） wheels. When the wheel porosity reaches 45%, the bending strength is still high up to 50 MPa with modified orderly pore distribution. A porous CBN wheel was fabricated with a total porosity around 30%. The grinding performance of the porous composite-bonded CBN wheel was evaluated in terms of specific force, specific grinding energy, and grinding temperature, which were better than those of the vitrified one under the same grinding conditions. Compared to the vitrified CBN wheel, clear straight cutting grooves and less chip adhesion are observed on the ground surface and there is also no extensive loading on the wheel surface after grinding.     

Grindability and Surface Integrity of Cast Nickel-based Superalloy in Creep Feed Grinding with Brazed CBN Abrasive Wheels

The technique of creep feed grinding is most suitable for geometrical shaping, and therefore has been expected to improve effectively material removal rate and surface quality of components with complex profile. This article studies experimentally the effects of process parameters (i.e. wheel speed, workpiece speed and depth of cut) on the grindability and surface integrity of cast nickel-based superalloys, i.e. K424, during creep feed grinding with brazed cubic boron nitride (CBN) abrasive wheels. Some important factors, such as grinding force and temperature, specific grinding energy, size stability, surface topography, microhardness and microstructure alteration of the sub-surface, residual stresses, are investigated in detail. The results show that during creep feed grinding with brazed CBN wheels, low grinding temperature at about 100 °C is obtained though the specific grinding energy of nickel-based superalloys is high up to 200-300 J/mm³. A combination of wheel speed 22.5 m/s, workpiece speed 0.1 m/min, depth of cut 0.2 mm accomplishes the straight grooves with the expected dimensional accuracy. Moreover, the compressive residual stresses are formed in the burn-free and crack-free ground surface.     

断续 CBN 砂轮缓进给磨削 K417 航空叶片材料的研究

 全面比较了用Al2O3和CBN磨削K417铸造高温合金时的磨削效果，指出：Al2O3不适于高效磨削K417之类的航空难加工材料，而CBN是实现该材料高效深切磨削的有效工具。通过大量实验，验证了断续CBN砂轮缓进给磨削K417时的技术优势，解决了树脂结合剂应用于断续磨削时所遇到的新问题。分析显示出该技术具有很好的应用前景和极大的推广价值。     

Comparative investigation on high-speed grinding of TiCp/Ti–6Al–4V particulate reinforced titanium matrix composites with single-layer electroplated and brazed CBN wheels

In order to develop the high-efficiency and precision machining technique of Ti Cp/Ti–6Al–4V particulate reinforced titanium matrix composites(PTMCs), high-speed grinding experiments were conducted using the single-layer electroplated cubic boron nitride(CBN) wheel and brazed CBN wheel, respectively. The comparative grinding performance was studied in terms of grinding force, grinding temperature, grinding-induced surface features and defects. The results display that the grinding forces and grinding temperature obtained with the brazed CBN wheel are always lower than those with the electroplated CBN wheel. Though the voids and microcracks are the dominant grinding-induced surface defects, the brazed CBN wheel produces less surface defects compared to the electroplated wheel according to the statistical analysis results. The maximum materials removal rate with the brazed CBN wheel is much higher than that with the electroplated one. All above indicate that the single-layer brazed CBN super-abrasive wheel is more suitable for high-speed grinding of PTMCs than the electroplated counterpart.     

电镀立方氮化硼砂轮在超深小孔磨削中的应用

电镀立方氮化硼砂轮在高精度、低表面粗糙度值的超深小孔磨削中,可大幅提高砂轮轴刚性,从而提高加工质量和生产效率。     

Performance evaluation of creep feed grinding of γ-TiAl intermetallics with electroplated diamond wheels

This paper evaluates the performance of creep feed grinding γ-TiAl intermetallic (Ti-45Al-2Mn-2Nb) using electroplated diamond wheels. Firstly, a comparative analysis with the grinding results by using electroplated CBN wheels was conducted, mainly involving abrasive wheel wear behavior and maximum material removal rate below surface burn limit. It was found that the diamond wheel would produce much better grinding results including lower wheel wear rate and higher maximum material removal rate. Then the surface integrity obtained at different level of material removal rate was characterized with the utilization of the diamond wheel. The poor ductility of this γ-TiAl intermetallic material was found to have a marginal effect on the surface integrity, as no severe surface defects such as material pullout were generated during the stable wheel wear stage. For the involved operating parameters, a deformation layer was produced with ∼10 μm or more in thickness depending on the material removal rate used. Meanwhile, a work-hardened layer extending to more than 100 μm was produced with a maximum microhardness of above 520 HV_0.05 (bulk value 360 HV_0.05). The residual stress remained compressive, with a value of above −100 MPa and even up to −500 MPa for an elevated material removal rate. Shearing chip was the main chip type, indicating good wheel sharpness in the grinding process.     

新型刚玉砂轮磨削GH4169镍基高温合金的性能评价研究

镍基高温合金是航空发动机部件的常用材料,其磨削加工存在工具损耗严重、寿命短等难题。针对3种新研制的刚玉砂轮(分别为粒度60#的微晶和单晶混合磨料砂轮、粒度60#的单晶刚玉砂轮,以及粒度70#的单晶刚玉砂轮),开展了GH4169镍基高温合金材料的磨削试验,从磨削力、磨削温度、砂轮磨损以及表面粗糙度等方面对3种砂轮的磨削性能进行了评价。结果表明,3种砂轮磨削GH4169材料在砂轮磨损和表面粗糙度方面未表现出明显差异,而通过对磨削力和磨削温度的综合评价发现粒度60#的单晶刚玉砂轮的磨削性能更优。3种砂轮磨削GH4169材料的磨削比在0.5~3之间。在正常磨削条件下,3种砂轮的磨削表面粗糙度Ra小于0.4μm。同时发现,砂轮磨损(主要包括磨粒的破碎和脱落)是造成磨削表面缺陷形成的重要原因。     

高纯钨磨削加工试验研究

为探究适用于高纯钨磨削加工的砂轮,使用80~#绿碳化硅砂轮和金刚石砂轮开展磨削对比试验,从工件表面粗糙度角度评价上述两种砂料对高纯钨磨削加工表面的影响。试验结果表明,绿碳化硅砂轮对应的工件得到了更理想的表面粗糙度。使用绿碳化硅砂轮开展工艺试验,分析在不同磨削参数下加工表面粗糙度的变化趋势,以此为依据对高纯钨磨削加工工艺参数进行评价与优化。综合考虑加工表面粗糙度以及加工效率,得出适合于钨磨削加工的参数为砂轮线速度v_s=23m/s、磨削深度a_p=8μm、工作台进给速度v_w=10m/min,该参数下得到的表面粗糙度均值为0.336μm。     

Suppression of Surface Burn in Grinding of Titanium Alloy TC4 Using a Self-inhaling Internal Cooling Wheel

Based on analysis of surface average temperature and burn degree, this article obtains the threshold temperature of surface burn in grinding titanium alloy with cup wheels. Meanwhile, the impact of the burn degree on the metallographic structure of workpiece surface and metallurgical phase transformations is investigated. In order to reduce the grinding temperature and improve the grinding efficiency, a self-inhaling structure cup segmented wheel is developed to generate internal cooling effect. The internal cooling technology is compared with traditional cooling conditions in the grinding experiments on TC4 (Ti-6Al-4V). The results indicate that the self-inhaling internal cooling wheel can reduce the grinding surface temperature by 30% or more, and the grinding efficiency doubles. Utilizing water-based semi-synthetic coolant, the segmented wheel with the self-inhaling structure can further reduce the grinding temperature by about 50%.     

钛合金风扇叶片磨抛加工性能试验研究

针对钛合金风扇叶片磨抛加工中砂轮易磨损、工件表面易烧伤的问题,开展了钛合金材料磨抛加工性试验研究,主要考察砂轮选型、磨抛工艺参数等关键因素对钛合金材料磨抛加工性的影响,并对试验结果进行了分析研究。试验结果表明,在保证工件表面加工质量(R_a0.8μm,表面无烧伤)的前提下,普通磨料砂轮GC46L10V磨抛加工钛合金的材料去除率和磨抛比分别可达5000mm~3/min和2.5,超硬磨料陶瓷结合剂CBN砂轮磨抛加工钛合金的材料去除率和磨抛比分别可达2000mm~3/min和4。基于研究结果,针对钛合金风扇叶片开展了砂带磨抛加工验证试验,工件加工质量良好。     

双电极接触放电修整金属结合剂金刚石磨轮

双电极接触放电是~项修整金属结合剂金刚石磨轮的新技术。它利用接触放电电蚀原理以达到去除磨轮的金属结合剂而修锐或整形磨轮。本文在论述修整机理的基础上,对其工艺规律进行了系统的分析与总结。     

Dimension Accuracy and Surface Integrity of Creep Feed Ground Titanium Alloy with Monolayer Brazed CBN Shaped Wheels

Titanium alloy tenon is creep feed ground with monolayer brazed cubic boron nitride (CBN) shaped wheels. The dimension accuracy of the tenon is assessed and the results indicate that it completely meets the requirement of blade tenon of aero-engine. Residual stresses, surface roughness, microstructure and microhardness are measured on ground surfaces of the specimen, which are all compared with that ground with vitrified CBN wheels. Under all the circumstances, compressive residual stress is obtained and the depth of the machining affected zone is found to be less than 40 μm. No phase transformation is observed at depths of up to 100 μm below the surface, though plastic deformation is visible in the process of grain refinement. The residual stress and microhardness of specimens ground with brazed CBN wheels are observed to be lower than those ground with vitrified ones. The arithmetic mean roughness (R_a) values obtained are all below 0.8 μm.     

Prediction on grinding force during grinding powder metallurgy nickel-based superalloy FGH96 with electroplated CBN abrasive wheel

In this article, a grinding force model, which is on the basis of cutting process of single abrasive grains combined with the method of theoretical derivation and empirical formula by analyzing the formation mechanism of grinding force, was established. Three key factors have been taken into accounts in this model, such as the contact friction force between abrasive grains and materials, the plastic deformation of material in the process of abrasive plowing, and the shear strain effect of material during the process of cutting chips formation. The model was finally validated by the orthogonal grinding experiment of powder metallurgy nickel-based superalloy FGH96 by using the electroplated CBN abrasive wheel. Grinding force values of prediction and experiment were in good consistency. The errors of tangential grinding force and normal grinding force were 9.8% and 13.6%, respectively. The contributions of sliding force, plowing force and chip formation force were also analyzed. In addition, the tangential forces of sliding, plowing and chip formation are 14%, 19% and 11% of the normal forces on average, respectively. The pro-posed grinding force model is not only in favor of optimizing the grinding parameters and improving grinding efficiency, but also contributes to study some other grinding subjects (e.g. abrasive wheel wear, grinding heat, residual stress).     

Interference and grinding characteristics in ultra-precision grinding of thin-walled complex structural component using a ball-end grinding wheel

As for ultra-precision grinding of difficult-to-process thin-walled complex components with ball-end grinding wheels, interference is easy to occur. According to screw theory and grinding kinematics, a mathematical model is established to investigate the interference and grinding characteristics of the ball-end wheel. The relationship between grinding wheel inclination angle, C axis rotation angle, grinding position angle and grinding wheel wear are analyzed. As the grinding wheel inclination angle increases, the C axis rotatable range decreases and the grinding position angle increases. The grinding position angle and wheel radius wear show a negative correlation with the C axis rotation angle. Therefore, a trajectory planning criteria for increasing grinding speed as much as possible under the premise of avoiding interference is proposed to design the grinding trajectory. Then grinding point distribution on the ball-end wheel is calculated, and the grinding characteristics, grinding speed and maximum undeformed chip thickness, are investigated. Finally, a complex structural component can be ground without interference, and surface roughness and profile accuracy are improved to 40.2 nm and 0.399 μm, compared with 556 nm and 3.427 μm before ultra-precision grinding. The mathematical model can provide theoretical guidance for the analysis of interference and grinding characteristics in complex components grinding to improve its grinding quality.     

激光宏观结构化金刚石砂轮磨削氧化铝工艺

为了研究砂轮表面结构化对砂轮磨削性能的影响,利用脉冲激光对树脂结合剂金刚石砂轮进行了表面宏观结构化。采用6种不同类型的金刚石砂轮表面宏观结构进行了氧化铝的磨削实验,建立了激光宏观结构化金刚石砂轮的磨削力模型,比较了6种不同激光宏观结构化金刚石砂轮与非结构化砂轮在不同磨削参数下磨削力的差异,分析了砂轮制造后的表面形貌与结构化砂轮的磨损特性。实验结果表明,砂轮宏观结构化对磨削性能有很大影响,激光宏观结构化砂轮的磨削力可以减小2. 5%~24. 5%,砂轮结构化后的表面形貌出现石墨化现象;宏观结构化砂轮沟槽边缘磨损加剧,但沟槽磨损并没有明显加快宏观结构化砂轮的磨损。     

氩气保护条件下钎焊单层金刚石砂轮的研究

 利用氩气作为保护气体,以 Ni-Cr合金粉末做钎料,适当控制钎焊温度、保温时间和冷却速度,实现了金刚石与钢基体的牢固的化学冶金结合。利用扫描电镜和 X射线能谱,结合 X射线衍射结构分析,发现在钎焊过程中 Ni-Cr合金中的 Cr元素分离在金刚石界面形成富 Cr层并与金刚石表面的 C元素反应生成Cr₃C₂ 和 Cr₇C₃,在钢基体结合界面上 Ni-Cr合金和钢基体中的元素相互扩散形成冶金结合,这是实现合金层与金刚石及钢基体之间都有较高结合强度的主要因素。并通过重负荷磨削实验进行验证取得较好的结果。     

TC4钛合金高效磨削加工用环形热管砂轮的研制

针对航空航天高强韧性难加工材料TC4钛合金在磨削加工中存在磨削温度高而导致工件表面烧伤的问题,提出利用热管换热技术冷却磨削弧区的新方法.分析了环形热管砂轮在加工中对磨削弧区的强化换热原理,并设计制作出能够用于磨削加工的环形热管砂轮,同时实现了对砂轮基体内环形管腔的密封、抽真空、精确注液与机械式真空封口.最后,在相同磨削工艺条件下,使用环形热管砂轮和无热管砂轮进行TC4钛合金缓进给深切磨削对比试验,验证了环形热管砂轮对磨削弧区温度的控制效果.试验结果表明:设计制作的环形热管砂轮在TC4钛合金高效磨削过程中可以有效降低磨削温度,避免工件表面出现烧伤.     

Analysis of grinding mechanics and improved grinding force model based on randomized grain geometric characteristics

Too high grinding force will lead to a large increase in specific grinding energy, resulting in high temperature in grinding zone, especially for the aerospace difficult cutting metal materials,seriously affecting the surface quality and accuracy. At present, the theoretical models of grinding force are mostly based on the assumption of uniform or simplified morphological characteristics of grains, which is inconsistent with the actual grains. Especially for non-engineering grinding wheel,most g...     

Modeling and experiment of grinding wheel axial profiles based on gear hobs

Hobbing is one of the crucial gear manufacturing processes with high precision and high efficiency. In order to improve the accuracy of hobbing and hob relief grinding, more precise grinding wheels are demanded for relief grinding in the production of gear hobs. In this paper, a new and accurate mathematical method for calculating the axial profile of grinding wheel based on the corresponding gear hob to be ground is proposed. Considering that most researches have been conducted to focus on the optimization of hob geometric feature and only can be applied to a specific type of hand of helix and rake angle of gear hobs. The method in this paper can be served as a general algorithm for generating axial profile of grinding wheels on the basis of the spatial envelope theory, the principle of coordinate system transformation, and studies on normal profile of single-tooth. The accuracy of grinding hobs is based on applying the approach in practical manufacturing. Taking two typical different kinds of pre-grinding gear hobs as examples for calculation and experiment, the results of tooth profile errors strengthen the position that the validity and feasibility of this method, it can be employed for gear hob design and grinding processing.     

Influence of alumina abrasive tool wear on ground surface characteristics and corrosion properties of K444 nickel-based superalloy

K444 nickel-based superalloy is an important material to manufacture the gas turbine due to its excellent mechanical properties at high temperatures and corrosion resistance. Currently,grinding is the mostly used method for the surface finish of the K444 alloy components. However,few studies worked on the effects of the abrasive tool wear on the ground surface characteristics and corrosion properties of K444 alloy. This study uses two different-type alumina abrasive tools, i.e.,white alumina(WA)...