power and wheel wear for grinding nickel alloy with plated

Power and Wheel Wear for Grinding Nickel Alloy with Plated

Substituting the measured power with the new wheels at v s = 12 and 30 m/s into Equation (3), the chip formation specific energy and the plowing force were obtained: u ch = 17.6 J/mm 3 and F’ pl = 0.42 N/mm. Being one of the most difficult-to-machine alloys, the chip formation specific energy of 17.6 J/mm 3 for grinding this nickel alloy is much higher than for grinding steels, which is about 13.8 J/mm 3 [20]. Based on models for grinding with conventional aluminum oxide wheels, a power model for grinding of a nickel alloy with plated CBN wheels was established and validated. Microscopic observations of the ground specimens reveal that thermal damage in the form of a White Etch Layer (WEL) appears only when grinding with a worn wheel under conditions that lead to high temperatures. Rise in grinding power with wheel wear was noted while grinding steel [5], nickel-based alloy [13, 15], and titanium alloy [14] employing electroplated cBN wheel. Reduction in surface roughness to

Get Price
power and wheel wear for grinding nickel alloy with plated

Power and Wheel Wear for Grinding Nickel Alloy with Plated

Based on models for grinding with conventional aluminum oxide wheels, a power model for grinding of a nickel alloy with plated CBN wheels was established and validated. Microscopic observations of the ground specimens reveal that thermal damage in the form of a White Etch Layer (WEL) appears only when grinding with a worn wheel under conditions that lead to high temperatures. Grinding power, forces, surface roughness, and radial wheel wear were measured. Specific material removal rate of 8 mm 3 /(mm.s) was reached in rough grinding using a wheel dressed for achieving surface roughness R a = 0.8 µm in finish grinding. It was found that shallow depths of cut combined with fast workspeeds, or less creep-feed modes, are more suitable for achieving high material removal rates with vitrified CBN grinding. During the grinding of nickel-based super alloy, due to their high strength at elevated temperatures and low heat conductivity, the CBN wheel is found to wear severely . The failure mechanisms can lead to an undesirable increase in power consumption and cutting forces, thermal damage to the work material as well as alterations in surface finish and form tolerance.

Get Price
study on wear of the grinding wheel with an abrasive

Study on wear of the grinding wheel with an abrasive

Power and wheel wear for grinding nickel alloy with plated CBN wheels CIRP Ann. Manuf. Technol. , 56 ( 2007 ) , pp. 343 - 346 Article Download PDF View Record in Scopus Google Scholar Guo et al. analytically correlated the grinding wheel wear with the grinding power consumption during the grinding of nickel alloy with electroplated CBN wheel. Recently, Shi et al. [17] improved such model by eliminating the requirement of a prior knowledge of the grit wear flat area and the regime of the average contact pressure. For grinding processes, this means that tool wear and performance need to be critically evaluated in their economic, environmental, and social impact. Tool wear affects several stakeholders. Different wear mechanisms on the grit and bond level lead to a change in tool profile and sharpness.

Get Price
technical solutions for cutting & grinding

TECHNICAL SOLUTIONS FOR CUTTING & GRINDING

Nickel alloy Titanium Aluminium• Minimum grinding wheel wearReduce grinding power Increase depth of cut Reduce wheel wear rate Increase metal removal rate 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. Alloy 400 N04400 66.5 31.5 Nickel-copper and nickel-iron alloys for sulfuric acid and Alloy 401 N04401 42.5 55.5 0.3 Mn 1.6 corrosion, and electrical applications. Have higher strength Alloy 450 C71500 30.0 68.0 0.7 Mn 0.7 B work hardened than Group A alloys.

Get Price
(pdf) grinding characteristics of a nickel-based alloy using

(PDF) Grinding characteristics of a nickel-based alloy using

Grinding characteristics of a nickel-b ased alloy using vitrified CBN wheels 3. to the presence of large stock allowances, grinding with large depths of cut is well. preferred. Creep-feed grinding[Show full abstract] directed to the effect of wheel wear and operating parameters on grinding of a nickel alloy. Wheels were worn to various stages and then used to perform grinding tests underA process for grinding deep profiled slots in a nickel-based alloy with electroplated cubic boron nitride (CBN) wheels and straight oil is presented. These slots were prepared by this process for further grinding with electroplated CBN quills to generate the final fir-tree slots in gas turbine disks. Fir-tree slots are usually machined using broaching.

Get Price
superabrasive grinding 101 | norton abrasives

Superabrasive Grinding 101 | Norton Abrasives

A 1987 study by Hitchiner and Wilks showed that when grinding nickel, the chemical wear of a diamond single-point turning tool exceeded abrasive mechanical wear by 105x, highlighting the importance of using CBN in these applications 2. Using CBN requires fewer wheel changes and machine downtime, offers low and controlled wear rates, and provides excellent thermal stability. grinding nickel-based alloys is their tendency to smear the grinding wheel active surface (GWAS) with the machined material chips [14]. This problem results from the most im-portantpropertiesofnickel-basedalloysthatarecharacterized by high durability, corrosive resistance, and fatigue endur-ance, as well as low heat conductivity and high malleability Nickel alloy Titanium Aluminium• Minimum grinding wheel wearReduce grinding power Increase depth of cut Reduce wheel wear rate Increase metal removal rate

Get Price
grinding characteristics of a nickel-based alloy using

Grinding characteristics of a nickel-based alloy using

2 Z. Shi et al. Keywords: grinding; vitrified CBN; wheel dressing; nickel-based alloy; grinding power; grinding forces; surface roughness; G-ratio. Reference to thisIt also relates to wheel wear. For example, where the grinding power is 25 watts per cubic millimetre of material removed per second for a particular workpiece material, the specific energy is 25 J/mm3. For a harder-to-grind workpiece material being machined with a fine-grain wheel, the specific energy might be as high as 200J/mm3. Abstract. Wear behavior and mechanism of single-layer brazed CBN abrasive wheels during creep-feed grinding nickel-based superalloy K424 was investigated. Grinding force and temperature acting on the abrasive wheels were measured. Optical microscopy and scanning electron microscopy were utilized to detect grain protrusion and wheel wear morphology.

Get Price
effect of vitrified bond microstructure and volume fraction

Effect of vitrified bond microstructure and volume fraction

Aspinwall DK, Soo SL, Curtis DT, Mantle AL (2007) Profiled superabrasive grinding wheels for the machining of a nickel based superalloy. CIRP Ann 56(1):335–338. Article Google Scholar 27. Guo C, Shi Z, Attia H, McIntosh D (2007) Power and wheel wear for grinding nickel alloy with plated CBN wheels. CIRP Ann 56(1):343–346 Abstract: An experimental study was undertaken to explore the conditions and performance on rough and finish grinding fir-tree root forms of turbine blades made of a nickel-based alloy using vitrified CBN wheels and water-based grinding fluid. This work was motivated by switching the grinding of fir-tree root forms from grinding with conventional abrasive wheels to vitrified CBN wheels for reducing overall production cost and enhancing productivity. Wear and life expectancy of a nickel-electroplated monolayer of cubic boron nitride grinding wheels are characterized based on the wheel surface topological evolution, observed after grinding

Get Price
wear of electroplated cbn grinding wheels | j. manuf. sci

Wear of Electroplated CBN Grinding Wheels | J. Manuf. Sci

Wear Mechanism of an Electroplated CBN Grinding Wheel During Grinding of a Nickel Base Alloy With Aqueous-Based Coolant Proc. of 2nd International Machining and Grinding Conference , pp. Finally, the grinding wheel wear, power consumption, and surface integrity are measured for both samples. Furthermore, the correlation of the material properties with the grindability is analyzed, which will shed light on the process optimization for high-quality SLM Inconel 718 grinding for its reliable service in practical applications. A 1987 study by Hitchiner and Wilks showed that when grinding nickel, the chemical wear of a diamond single-point turning tool exceeded abrasive mechanical wear by 10 5 x, highlighting the importance of using CBN in these applications 2. Using CBN requires fewer wheel changes and machine downtime, offers low and controlled wear rates, and provides excellent thermal stability.

Get Price
effect of process parameters on surface roughness during

Effect of process parameters on surface roughness during

Guo et. al. [6] have studied the effect of both wheel wear and process parameters on the grinding performance of plated CBN wheel on a nickel alloy to obtain particular model. Liu et. al. [7] have researched the stringent requirements for grinding wheels include low damage on ground surfaces, self-dressing ability, consistent performance, longThe objective is to explore the feasibility to grind titanium alloys with electroplated CBN wheels and high pressure wheel surface cleaning fluid for enhancing material removal rates. Straight surface grinding experiments were conducted on titanium alloy blocks in both shallow depth of cut and creep-feed modes. Finally, surface integrity by using a SA wheel and the different grinding depth was studied and analyzed by the grinding temperature and the grinding force. It was possible to conclude that better surface can be achieved by using a SA, and taking a p = 0.005 mm, v w = 16 m/min, v s = 25 m/s for grinding Inconel718.

Get Price
superabrasive grinding 101 - aerospace manufacturing and design

Superabrasive grinding 101 - Aerospace Manufacturing and Design

Cubic boron nitride (CBN) is a superabrasive traditionally used to grind steels and nickel alloys. Though not as hard as diamond (4,500kg/mm 2 vs. 9,000 kg/mm 2), CBN is not chemically reactive with ferrite-based and nickel alloys, allowing it to outperform diamond-based grinding wheels in life and material removal rates on these materials 1. Abstract: To explore the micro-grinding surface quality of nickel-based superalloy, orthogonal experiments of three factors and five levels on nickel-based superalloy K445 were performed using a micro-grinding tool with # 500 grains and 0.9mm diameter. The influencing factors on the surface roughness were clarified according to the rangeA valuable tool for comparing grinding wheels, evaluating grinding cycles, reducing cycle-times and troubleshooting grinding problems. What it is: The Grindometer is a device that measures the grinding-wheel spindle power, in kilowatts or horsepower. This signal – when plotted vs. time – gives valuable information that can be used for

Get Price
time dependent behavior analysis of inconel- scientific.net

Time Dependent Behavior Analysis of Inconel- scientific.net

The time dependent behavior of grinding is expressed as the change of process output measures as a function of time during grinding. Although the wheel capability will be restored by dressing, the time dependent behavior of grinding during one dressing skip is determinant on the grinding quality variation in terms of surface integrity and workpiece geometric accuracy. are the reduction of wheel wear and cutting forces. Through over this study it has been proven that vibration assisted grinding allows the wheel to cut in two directions and that will increase the material removal rate reduce the wheel wear, cutting forces and also the power consumption. 273. 2016. Wear mechanisms of WC coated and uncoated tools in finish turning of Inconel 718. A Bhatt, H Attia, R Vargas, V Thomson. Tribology International 43 (5-6), 1113-1121. , 2010. 265. 2010. Characterization of the dry high speed drilling process of woven composites using Machinability Maps approach.

Get Price
mechanics of loading for electroplated cubic boron nitride

Mechanics of Loading for Electroplated Cubic Boron Nitride

Wheel loading was the primary cause for the significant decrease in grinding wheel life for the current formulation of water-based lubricants tested. Evidence of the specific sequence in the deposition process has been captured through extended evaluation and characterization of the grinding wheel surface and adherent alloy material. A good grinding oil is the best lubricant for crush form and thread grinding. Sodium chromate can be added to sal soda solutions to inhibit corrosion of the equipment. In general, silicon carbide grinding wheels give best results on alloys of groups A, B, D-1 and E; aluminum oxide wheels are best for alloys of groups C and D-2. Because rapid wheel wear was observed, it wasn’t practical to continue increasing removal rates when grinding in water soluble coolant beyond 5 in³/min/in (50 mm³/sec/mm). However when grinding with oil coolant, removal rates as high as 18 in³/min/in (180 mm³/sec/mm) with minimal impact on G-ratio are possible.

Get Price