Creep feed profile grinding of Ni-based superalloys with ultrafine-polycrystalline cBN abrasive grits

This paper presents the grinding characteristics of a newly developed ultrafine-polycrystalline cBN abrasive grit in creep feed profile grinding of Nickel-based superalloys. Experiments for producing a rectangular-shaped groove on a flat surface in one pass by creep feed grinding have been carried out using the new polycrystalline cBN (PcBN-U) grit and a representative conventional monocrystalline cBN (McBN-B1) grit. The grinding forces in grinding with PcBN-U grits are reduced by 20 30% compared with McBN-B1 grits. When grinding with PcBN-U grits, both radial wear and profile wear are less, and hence the grinding ratio is around 4 times higher than that with McBN-B1 grits. The size of grit fracture during the grinding process with PcBN-U grits is smaller than that with McBN-B1 grits. It gives lower wheel wear rate and longer wheel life in grinding with PcBN-U than with McBN-B1.     

A frequency-domain grinding force model-based approach to evaluate the dynamic performance of high-speed grinding machine tools

This article provides an integrated approach to evaluate grinding machine's dynamic performance in speed range by examining both the manufacturing process and the machine tool. This approach considers the dynamic grinding force as a starting point. The dynamic change of the cutting depth in the grinding process is studied first. Then, based on the dynamic model of grinding process developed in previous studies, the dynamic forces of the manufacturing process are predicted. By analyzing the grinding force model in the frequency-domain and the frequency response function, the root mean square values of the machine vibration are calculated. The evaluation works by comparing the variation and trend of the vibration level. The proposed evaluation method is then applied to a physical grinding machine. The dynamic performance obtained from the experiment matches the predicted trend in the models. In addition, this method can be used to inspect and optimize the design of the machine's spindle system. For the grinding process that requires a high dynamic performance, this method also provides reference for the speed selection within all speed range.     

树脂结合剂金刚石砂轮磨削铁氧体陶瓷磨削力的实验研究

通过一系列的实验，研究了树脂结合剂金刚石砂轮磨削铁氧体陶瓷材料时磨削力的变化规律及其特点。通过磨削对比实验方法分析磨削铁氧体陶瓷时，磨削用量对磨削力大小的影响。通过砂轮速度，磨削深度，横向进给速度和纵向进给速度等因素影响磨削力大小变化的数据及磨削力信号特征处理的分析和比较，分析了对铁氧体材料磨削时产生的磨削力影响的一些规律，表明铁氧体陶瓷磨削时磨削力变化的特有规律．     

Creep feed grinding induced gradient microstructures in the superficial layer of turbine blade root of single crystal nickel-based superalloy

The service performance of the turbine blade root of an aero-engine depends on the microstructures in its superficial layer. This work investigated the surface deformation structures of turbine blade root of single crystal nickel-based superalloy produced under different creep feed grinding conditions. Gradient microstructures in the superficial layer were clarified and composed of a severely deformed layer (DFL) with nano-sized grains (48–67 nm) at the topmost surface, a DFL with submicron-sized grains (66–158 nm) and micron-sized laminated structures at the subsurface, and a dislocation accumulated layer extending to the bulk material. The formation of such gradient microstructures was found to be related to the graded variations in the plastic strain and strain rate induced in the creep feed grinding process, which were as high as 6.67 and 8.17 × 107 s?1, respectively. In the current study, the evolution of surface gradient microstructures was essentially a transition process from a coarse single crystal to nano-sized grains and, simultaneously, from one orientation of a single crystal to random orientations of polycrystals, during which the dislocation slips dominated the creep feed grinding induced microstructure deformation of single crystal nickel-based superalloy.     

Experimental investigation on high-efficiency grinding of Inconel 718 with heat pipe grinding wheel

Grinding heat is a significant problem for grinding difficult-to-machine materials such as nickel-based superalloys, which restricts their applications. A majority of existing cooling methods ensure cooling by simply increasing the volume of coolant. However, lubricants often lose efficacy due to film boiling and have adverse health and environment effects. To dissipate grinding heat in the contact zone and guarantee workpiece surface quality, a novel cooling method that dissipates grinding heat assisted by forming rotating heat pipe inside the grinding wheel (HPGW) is proposed. Tests were performed to determine its heat transfer capacity in high-efficiency grinding of Inconel 718 alloy. The results show that grinding with HPGW leads to lower grinding temperatures and lower thermal damages to the workpiece when compared to grinding with non-HPGW. Better heat transfer capacity of HPGW is explained by heat transfer resistance analysis for both grinding wheels. The analysis proves that the value of HPGW is one order of magnitude lower than non-HPGW. Furthermore, in-depth studies of the ground surface showed no changes in microstructure or microhardness for the workpiece when using HPGW, whereas different degrees of burn were seen as indicated by different temper colors and corresponding changes in microstructure and microhardness.     

Experimental study of grinding fluids for abrasive-belt grinding of stainless steel

A number of ferritic stainless steels with high corrosion resistance have recently been developed, but these steels are known to be difficult to grind in coated abrasive-belt grinding operations. In order to formulate or select an optimum oil-based grinding fluid with which such stainless steels can be successfully ground, an optimum base oil was first experimentally selected, and then additives were evaluated for their effect in improving abrasive-belt grinding performance. A paraffinic mineral oil having a certain viscosity was found to be suitable for the base oil. Chemical grinding oil additives were found markedly effective in improving the abrasive-belt grinding performance for both 19Cr-2Mo ferritic stainless steel and SUS 304 austenitic steel, with those containing sulphur or chlorine being superior to those containing phosphorus, fatty acid or alcohol. Among all the additives tested, chemically active oils, such as sulphurized mineral oil, exhibited the best performance. Effects of chlorinated paraffins on the grinding performance could be perceived but were not so great as those of sulphur-series additives. The addition of TCP (tricresyl phosphate) to the grinding oil containing sulphur reduced metal removal in the case of 18Cr-2Mo ferritic stainless steel (SUS 444). In the case of SUS 430 ferritic stainless steel, however, TCP increased metal removal for a comparatively low sulphur concentration, but, above an optimum concentration of 0.4 wt% S, metal removal was reduced by TCP addition. A comparison of sulphur-series additives added to a sulphurized paraffinic mineral oil showed that nonyl polysulphide was superior to any other additives for improving the grinding performance in 19Cr-2Mo steel (SUS 444) and SUS 430. Excess addition of sulphurized fatty oil to a grinding fluid lowered the cutting ability of abrasive grains.     

A study on wear mechanism and wear reduction strategies in grinding wheels used for ELID grinding

Metal-bonded superabrasive diamond grinding wheels have superior qualities such as high bond strength, high stability and high grindability. The major problems encountered are wheel loading and glazing, which impedes the effectiveness of the grinding wheel. Electrolytic in-process dressing (ELID) is an effective method to dress the grinding wheel during grinding. The wear mechanism of metal-bonded grinding wheels dressed using ELID is different form the conventional grinding methods because the bond strength of the wheel-working surface is reduced by electrolysis. The reduction of bond strength reduces the grit-depth-of-cut and hence the surface finish is improved. The oxide layer formed on the surface of the grinding wheel experiences macrofracture at the end of wheel life while machining hard and brittle workpieces. When the wheel wear is dominated by macrofracture, the wheel-working surface is free from loaded chips and worn diamond grits. When the oxide layer is removed from the wheel surface, the electrical conductivity of the grinding wheel increases, and that stimulates electrolytic dressing. The conditions applied to the pulse current influence the amount of layer oxidizing from the grinding wheel surface. Longer pulse ‘on’ time increases the wheel wear. Shorter pulse ‘on’ time can be selected for a courser grit size wheel since that type of wheel needs high grinding efficiency. Equal pulse ‘on’ and ‘off’ time is desired for finer grit size wheels to obtain stable and ultraprecision surface finish.     

Tribological characteristics in high-speed grinding of alumina with brazed diamond wheels

In this work, two brazed diamond wheels fabricated by brazing in vacuum were used to grind alumina at different grinding speeds. During the process, the horizontal and vertical grinding forces were measured by a force measurement device. The grinding forces, specific grinding energy, and friction in grinding of alumina at low and at high speeds were investigated. The results show that the friction coefficient decreases with the increase of the grinding speed and also relates to the grinding mode. A nearly proportional relationship between grinding power per unit width (P _m ) and the rate of plowed surface area generated per unit time per unit width (S _w ) reveals the effects of friction in grinding and most of the grinding energy is expended by friction. The surface energy per unit area generated by plowing friction (J _s ) for high-speed grinding is found to be lower than for low-speed grinding.     

工程陶瓷恒力磨削金刚石砂轮钝化规律研究

通过一系列试验建立了恒力磨削条件下砂轮全钝化周期的钝化曲线,并通过相应的数学手段对各个阶段的砂轮钝化特征和磨削能力进行分析.结果表明:初期钝化阶段的钝化曲线随时间的变化是由凹到凸的过程,与砂轮磨损过程有很大的区别.初期钝化阶段砂轮钝化速度大大低于其他两个阶段,砂轮具有很强的磨削能力,这一特征的潜在应用价值非常高.正常磨损阶段砂轮的钝化与砂轮磨损规律一致,呈线性增大趋势.     

A comparative study of residual stress and affected layer in Aermet100 steel grinding with alumina and cBN wheels

Residual stresses induced by finish machining processes have significant effect on fatigue strength of ultra-high strength steel in large structures. In this study, an experimental investigation was carried out to explore the residual stress and affected layer in grinding Aermet100 by using a resin bond white alumina (WA) wheel and cubic boron nitride (cBN) wheel, respectively. The grinding force and temperature were measured, and then the affected layer of residual stress, microhardness, and microstructure by a WA and a cBN wheel was obtained. The comparisons of surface residual stress studies and thermal–mechanical coupling mechanism on the affected layer were discussed in light of the current understanding of this subject. Experimental results show that grinding with cBN wheel can provide compressive residual stress and a smaller affected layer owing to its better thermal conductivity; the coupling effect of wheel speed and grinding depth plays a more significant role on surface residual stress; when grinding with parameters v _w?=?18 m/min, v _s?=?14 m/s, and a _p?=?0.01 mm, compressive residual stress and hardening effect appeared on ground surface, and the depth of residual stress layer is 40~50 μm; the depth of hardened layer is 30~40 μm and the depth of plastic deformation layer is 5~10 μm.     

磨削粗糙度在线检测方法的实验研究

本文对基于摩擦声发射信号的磨削粗糙度在线检测方法进行了实验研究。实验结果表明，采用声发射传感器探头与磨削表面摩擦产生的声发射信号的特征可以对磨削表面粗糙度进行评价，建立了摩擦声发射信号特征与磨削表面粗糙度之间的对应关系，并通过实验对该方法的可行性进行了实测。结果表明，探针与工件表面摩擦声发射信号的FFT和RMS特征与磨削粗糙度有很好的对应关系，可用于磨削表面粗糙度的在线检测。     

The optimisation of the grinding of silicon carbide with diamond wheels using genetic algorithms

Modelling and optimisation are necessary for the control of any process to achieve improved product quality, high productivity and low cost. The grinding of silicon carbide is difficult because of its low fracture toughness, making it very sensitive to cracking. The efficient grinding of high performance ceramics involves the selection of operating parameters to maximise the MRR while maintaining the required surface finish and limiting surface damage. In the present work, experimental studies have been carried out to obtain optimum conditions for silicon carbide grinding. The effect of wheel grit size and grinding parameters such as wheel depth of cut and work feed rate on the surface roughness and damage are investigated. The significance of these parameters, on the surface roughness and the number of flaws, has been established using the analysis of variance. Mathematical models have also been developed for estimating the surface roughness and the number of flaws on the basis of experimental results. The optimisation of silicon carbide grinding has been carried out using genetic algorithms to obtain a maximum MRR with reference to surface finish and damage.Nomenclature C constant in mathematical model - C₁ constant in surface roughness model - C₂ constant in the number of flaws model - d depth of cut, m - dof degrees of freedom - f table feed rate, mm/min - M grit size (mesh) - MRR material removal rate, mm³/mm width-min - N_c number of flaws measured - R_a surface roughness measured, m - Y machining response - depth of cut exponent in mathematical model - ₁ depth of cut exponent in surface roughness model - ₂ depth of cut exponent in number of flaws model - feed rate exponent in mathematical model - ₁ feed rate exponent in surface roughness model - ₂ feed rate exponent in number of flaws model - grit size exponent in mathematical model - ₁ grit size exponent in surface roughness model - ₂ grit size exponent in number of flaws model     

扰流板安装方向对高速列车的气动性能影响

采用结构网格对计算区域进行离散,采用DES湍流数值模拟方法,研究高速列车尾部横向、竖向或斜向地安装扰流板对车的气动性能影响,找出扰流板安装的合理方向。研究结果表明:安装横向或竖向扰流板后,尾部的气动阻力变大,升力减小,而安装斜向扰流板后,尾部的气动阻力与升力均减小。因此,列车尾部扰流板的合理方向为斜向安装。     

Study on coolant-induced hydrodynamic pressure in contact zone while deep grinding with CBN wheels

The use of coolant has been considered an effective way to avoid workpiece burn in the grinding process. Hydrodynamic pressure induced by coolant in the contact zone is always measured to characterize the coolant condition in the contact zone. In this study, grinding experiments with a cubic boron nitride wheel were first performed to determine the evolution of hydrodynamic pressure during the grinding process. The experimental results showed that when burn happened, hydrodynamic pressure was at a low level and decreased gradually while the temperature and power signals fluctuated sharply. A theoretical calculation model and a 3D air–liquid two-phase numerical simulation model were subsequently constructed to predict the hydrodynamic pressure. Both theoretical calculation and numerical simulation results showed that the hydrodynamic pressure in such a case is in inverse proportion to the gap distance between the wheel and the workpiece. The theoretical calculation results are higher than the numerical simulation results. Furthermore, the experimental results correspond to the results of the 3D air–liquid two-phase simulation, which confirms the validity of this simulation. This article presents an accurate approach to predict hydrodynamic pressure, which provides an effective analytical method of studying and avoiding workpiece burn.     

暴风雪条件下列车气动特性及倾覆稳定性分析

为研究高速列车在恶劣气候条件(暴风雪)下的气动特征及安全性等问题,将采用欧拉双流体模型进行数值模拟的方法应用到对CRH-2高速列车在暴风雪条件下的研究中。开展了对列车周围空气流场的分析,建立了流场与列车受力之间的关系,提出了有关列车稳定性的临界倾覆速度的计算方法;在强侧风及强侧风和强降雪耦合的两种情况下对列车的倾覆稳定性进行了评价。研究结果表明,两种情况下列车倾覆临界速度的趋势相似,而且在强侧风及强降雪情况下,列车的侧向力系数、侧滚力矩系数比较单纯的侧风天气条件显著增加;降雪工况下列车的临界速度比无降雪时减小20%~50%,即降雪条件下,列车更容易发生倾覆;计算结果可以为在暴风雪条件下列车的安全行驶提供参考。     

球墨铸铁纳米粒子射流微量润滑磨削性能的实验研究

主要对纳米粒子射流微量润滑磨削性能进行实验评价.采用K-P36数控平面磨床,选取干磨削、浇注式磨削、微量润滑磨削和纳米粒子射流微量润滑磨削4种工况条件,分别从磨削力、磨削G比率、磨削温度和表面粗糙度方面进行磨削性能评价,结果表明:纳米粒子射流微量润滑磨削改善了换热能力,与干磨削相比降低了将近150℃,干磨削得到的工件表面粗糙度Ra值为1.2μm,纳米粒子射流微量润滑磨削Ra值为0.58 μm,工件表面质量显著提高;在纳米粒子的润滑作用下,得到的磨削力较稳定,且比干磨削和微量润滑磨削得到的磨削力减小15％以上;纳米粒子射流微量润滑磨削G比率在4种工况中最高,值为33,干磨削仅为12,比其他工况增大约一倍,砂轮的磨损明显减小,延长砂轮使用寿命.     

影响砂轮切削性能的原因及改善途径

根据磨削加工中砂轮的形貌特征、切削机理及状态变化,分析了砂轮钝化的原因,提出了改善砂轮磨削性能与加工效率的措施。     

Wear of the blade diamond tools in truing vitreous bond grinding wheels: Part II. Truing and grinding forces and wear mechanism

Truing and grinding forces and the wear mechanism of particle and rod diamond blade tools used to generate precise and intricate forms on rotating vitreous bond silicon carbide grinding wheels are presented. A Hall effect sensor was used to measure the change of grinding spindle power during truing and grinding. A signal processing procedure was developed to identify individual truing passes and to extract the average, peak-to-valley, and standard deviation of the variation of truing force for each pass. The truing force data and SEM micrographs of worn surfaces on blade tools reveal micro- and macro-fracturing of the diamond. The attritious and erosion wear of the diamond rod and particle, erosion of the metal bond, and pulling-out of the diamond particle are also identified. Grinding force data shows that, for the same truing parameters, a wheel trued by the rod diamond blade tool has higher grinding forces than one trued by a particle diamond blade tool.     

Experimental investigation of contact behaviour in grinding

The nature of the wheel and workpiece contact in grinding has a strong effect on the temperature, force and surface integrity as well as wheel wear in grinding. An applied power source method was used to measure the real contact length. The interpretation of contact length measurements is discussed. Experimental measurements of contact length in grinding show that the contact length is much larger than the geometrical contact length. This difference is most significant in fine grinding and in the sparkout stage of plunge grinding. The difference also increases when the table speed is increased. The contact length in wet grinding is longer than the contact length in dry grinding. The contact length when grinding cast iron is shorter than the contact length when grinding mild steel. It is found that grinding geometry, grinding force and the roughness of the grinding wheel have independent effects on the contact length. The newly developed contact length model by the authors describes these effects quantitatively. These results also show the importance of the roughness factor, R_r, for analysis of the contact behaviour in grinding processes.