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TECHNICAL PAPERS

Wear of Electroplated CBN Grinding Wheels

[+] Author and Article Information
Z. Shi

Aerospace Manufacturing Technology Center, Institute for Aerospace Research, National Research Council Canada, Montreal, QC H3T 2B2, Canadazhongde.shi@nrc-cnrc.gc.ca

S. Malkin1

 University of Massachusetts, Engineering Lab Building, Amherst, MA 01003malkin@ecs.umass.edu

1

To whom correspondence should be addressed.

J. Manuf. Sci. Eng 128(1), 110-118 (Jul 05, 2005) (9 pages) doi:10.1115/1.2122987 History: Received March 31, 2005; Revised July 05, 2005

An investigation is reported on the wear of single-layer electroplated cubic boron nitride (CBN) grinding wheels and how the wear process affects the wheel topography and grinding behavior. Internal cylindrical and straight surface grinding experiments were conducted over a wide range of conditions on hardened bearing steel with wheels containing different abrasive grain sizes. The radial wheel wear was characterized in each case by an initial transient at a progressively decreasing rate to a steady-state wear regime at a nearly constant rate until the end of the wheel life. Wheel wear during the initial transient was found to be mainly due to pullout of the most protruding weakly held grains, and the radial wheel wear in the steady-state regime was dominated by grain fracture. The wear rate in the steady-state regime for various grinding conditions and grain sizes was found to be directly related to the undeformed chip thickness. Dulling of the grain tips by attrition and fragmentation caused an increase in the grinding power. Wheel wear was accompanied by a progressive increase in the active grain density and a corresponding decrease in surface roughness. The surface roughness was found to depend mainly on the active grain density and is insensitive to the operating parameters.

Copyright © 2006 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Illustration of CBN grains on wheel surface (6,11)

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Figure 2

SEM micrograph of new electroplated CBN wheel surface (120 grit)

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Figure 3

Effect of grain dimension on areal packing density

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Figure 4

Measured grain height distribution

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Figure 5

Mean and standard deviation versus grain dimension

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Figure 6

SEM micrographs of used wheel surface (120 grit, w=98μm)

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Figure 7

Radial wheel wear versus accumulated removal per unit width

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Figure 8

Wheel topography versus accumulated removal per unit width

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Figure 9

Power and specific energy versus accumulated removal per unit width

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Figure 10

Surface roughness versus accumulated removal per unit width

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Figure 11

Wheel wear, power, and roughness versus accumulated removal per unit width

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Figure 12

Radial wheel wear consisting of initial transient and steady states

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Figure 13

Normalized radial wear intercept versus grain dimension

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Figure 14

Normalized active grain density versus normalized radial wheel wear

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Figure 15

Grains versus radial wheel wear

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Figure 16

Ratio of measured to theoretical grain pullouts at w0

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Figure 17

Effect of grain pullout on initial transient radial wear

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Figure 18

Normalized radial wear rate versus undeformed chip thickness

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Figure 19

Steady-state G ratio versus grain dimension

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Figure 20

Grinding power versus smooth wear flat area

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Figure 21

Grinding power versus equivalent wear flat area

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Figure 22

Surface roughness versus active grain density

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