Fluid Performance Study for Groove Grinding a Nickel-Based Superalloy Using Electroplated Cubic Boron Nitride (CBN) Grinding Wheels

[+] Author and Article Information
Frank C. Gift, Wojciech Z. Misiolek

Industrial and Systems Engineering Department, Lehigh University, Bethlehem, PA 18015

J. Manuf. Sci. Eng 126(3), 451-458 (Sep 07, 2004) (8 pages) doi:10.1115/1.1763181 History: Received August 01, 2003; Revised November 01, 2003; Online September 07, 2004
Copyright © 2004 by ASME
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Illustration of the layout of fluid delivery system in the grinding setup, where feed (f) and wheel rotation (v) are in opposite directions
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Contrast in performance between the straight petroleum oil and the three water-based fluids in terms of cutting (tangential) force
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Optical stereomicroscope images of typical deposits observed on the grinding wheel surface after reaching failure in the water-based fluid trials, both separated and (b) adjoining deposits
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Single CBN grain encapsulated by adhering Ni-based superalloy deposit
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(a) SEM image showing chip adhesion on the rake face and clearance face of a CBN grain (b) accompanying schematic to illustrate features in the image
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Deposit adhesion on the rake face of the CBN abrasive with the bulk of the deposit capping the clearance face and adjacent abrasive grains
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Intimate contact between the deposit and top of the rake face (circled) is observed, with little interaction between the deposit underside and the bond matrix
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Sharp CBN abrasive grains are observed after 120 grinding passes in the straight oil product
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The neat oil fluid trial had (a) a surface clear of deposits, with (b) no significant signs of wear other than CBN grit pullout (circled)
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Image of new electroplated CBN grinding wheel with missing abrasive grains on the wheel surface
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Images of CBN abrasive grains from a control sample
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The rough faces of the CBN grains commonly observed in the control sample shown on (a) several different faces and (b) at high magnification
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Schematic of (a) three abrasive grains and how they might be oriented on the wheel surface and (b) the mechanics of chip formation
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Schematic of the (a) orientation of fluid spray in a conventional scrubber nozzle layout and (b) its relation to a chip adhering to the CBN grain’s rake face
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Fluid flow directions that would be effective in shearing adhering chips off of the CBN grain
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Proposed layout of scrubber nozzles, oriented on both sides of the wheel (A/A and B/B at different locations within the depth of the page) for high pressure fluid delivery that is effective in wheel cleaning




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