Wear behaviors of electroplated CBN grinding wheel with orderly-micro-grooves in grinding narrow-deep slot

• Published in: International journal of advanced manufacturing technology 2024-03, Vol.131 (5-6), p.2857-2868
• Main Authors: Mao, Cong, Li, Xiang, Zhang, Mingjun, Zhang, Jian, Zhang, Weiyou, Luo, Yuanqiang, Tang, Weidong, Tang, Kun, Bi, Zhuming, Hu, Yongle, Lin, Zhenheng
• Format: Article
• Language: English
• Subjects: Adhesion; Behavior; CAE) and Design; Carrying capacity; Computer-Aided Engineering (CAD; Cutting parameters; Engineering; Fractures; Grinding wheels; Grooves; Industrial and Production Engineering; Mechanical Engineering; Media Management; Original Article; Sharpening; Tool life; Wear mechanisms; Workpieces
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-12509-4

A grinding wheel with orderly-micro-grooves is a new type of structured grinding wheel for grinding narrow-deep slots. It can improve the carrying capacity of the coolant in the grinding zone effectively. The wear and evolution of grains directly determine the sharpness of the grinding wheel, and this affects the grinding performance in terms of efficiency, surface integrity, and tool life. In order to design the grinding wheel for minimized wear in its use, this study elucidates the wear behaviors of the grinding wheel with orderly-micro-grooves in grinding narrow-deep slots. Through the comparative experiments of the grinding narrow-deep slot, the impacts of micro-grooves on the wear behaviors of the grinding wheel are evaluated, and the wear behavior of the grains on the cut-in edge, cut-out edge, cylindrical surface, and side surface is observed, respectively. The analysis of the grinding ratio, grinding force, and force ratio further verifies the analysis of the wear mechanism and the grinding performance. It is found that (1) the macro-fracture of grain on the cut-in edge occurred due to the large cutting thickness increasing the load of the grain; (2) the debonding phenomenon reduces the anchoring force of the grain, and this tends to pull out the grain on the cut-out edge; (3) due to the adhesion action of the micro-welds, the main failure behavior of the grain on the cylindrical surface is chip adhesion, and the bridge adhesion appears at the small inter-grain space; (4) grains on the side surface are less engaged in removing workpiece materials, the cutting depths of the grains in the middle and inner zones are ignorable, and attrition wears and micro-fractures occur on the grains on the side surface. The grinding force and force ratio variation further verifies that the grinding wheel with orderly-micro-grooves can achieve self-sharpening to maintain excellent grinding performance.