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Research Papers

Grinding of Chromium Carbide Coatings Using Electroplated Diamond Wheels

[+] Author and Article Information
Zhongde Shi

Structures, Materials, and
Manufacturing Laboratory,
National Research Council Canada,
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Zhongde.shi@nrc.ca

Amr Elfizy

Pratt & Whitney Canada,
1000 Marie-victorin,
Longueuil, QC J4G 1A1, Canada
e-mail: Amr.elfizy@pwc.ca

Helmi Attia

Fellow ASME
Structures, Materials, and
Manufacturing Laboratory,
National Research Council Canada,
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Helmi attia@nrc.ca

Gilbert Ouellet

Pratt & Whitney Canada,
1000 Marie-victorin,
Longueuil, QC J4G 1A1, Canada
e-mail: gilbert.ouellet31mars@gmail.com

1Corresponding author.

Manuscript received March 31, 2017; final manuscript received June 22, 2017; published online November 2, 2017. Assoc. Editor: Mark Jackson.

J. Manuf. Sci. Eng 139(12), 121014 (Nov 02, 2017) (6 pages) Paper No: MANU-17-1207; doi: 10.1115/1.4037183 History: Received March 31, 2017; Revised June 22, 2017

This paper reports an experimental study on grinding of chromium carbide coatings using electroplated diamond wheels. The work was motivated by machining carbide coatings in gas turbine engine applications. The objective is to explore the process conditions and parameters satisfying the ground surface quality requirements. Surface grinding experiments were conducted with water-based grinding fluid on chromium carbide coated on flat surfaces of aluminum blocks for rough grinding at a fixed wheel speed vs = 30 m/s, and finish grinding at vs = 30, 60 m/s. The effects of depth of cut and workspeed on grinding power, forces, and surface roughness were investigated for each of the wheel speeds. Material removal rate Q = 20 mm3/s for rough grinding at a grinding width b = 101.6 mm was achieved. It was found that the maximum material removal rate achievable in rough grinding was restricted by chatters, which was mainly due to the large grinding width. The specific energy ranged from 27 to 59 J/mm3 under the tested conditions. Surface roughness Ra = 3.5–3.8 μm were obtained for rough grinding, while Ra = 0.6–1.5 μm were achieved for finish grinding. Surface roughness was not sensitive to grinding parameters under the tested conditions, but was strongly dependent on the diamond grain sizes. Imposing axial wheel oscillations to the grinding motions reduced surface roughness by about 60% under the tested condition. It was proved that it is feasible to grind the chromium carbide coating with electroplated diamond wheels.

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References

Zelwer, O. , and Malkin, S. , 1980, “ Grinding of WC-Co Cemented Carbides—Part I,” Ind. Diamond Rev., 4, pp. 133–139.
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Shi, Z. , Attia, H. , Chellan, D. , and Wang, T. , 2008, “ Creep-Feed Grinding of Tungsten Carbide Using Small Diameter Electroplated Diamond Wheels,” Ind. Diamond Rev., 4(08), pp. 65–69. https://static-content.springer.com/esm/art%3A10.1007%2Fs00170-011-3706-7/MediaObjects/170_2011_3706_MOESM8_ESM.pdf
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Guo, C. , Shi, Z. , Attia, H. , and Mclntosh, D. , 2007, “ Power and Wheel Wear for Grinding of Nickel Alloys With Plated CBN Wheels,” Ann. CIRP, 56(1), pp. 343–346. [CrossRef]
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Figures

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Fig. 1

Pictures of experimental setup

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Fig. 2

Pictures of wheel core machining

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Fig. 3

Pictures of workpiece and coating

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Fig. 4

Micrograph of coating and substrate

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Fig. 5

Topography of coating surface

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Fig. 6

An example of measured horizontal forces

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Fig. 7

An example of net forces and power

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Fig. 8

Effect of depth of cut on forces

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Fig. 9

Effects of depth of cut on power

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Fig. 10

Effects of depth of cut on surface roughness

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Fig. 11

An example of ground surface

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Fig. 12

Surface roughness of finish grinding

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Fig. 13

Horizontal and vertical spark-out forces

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Fig. 14

Surface roughness profiles

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Fig. 15

Micrograph of worn wheel surface

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