Papers by Keyword: Electroplated CBN Wheel

Abstract: A process for grinding deep profiled slots in a nickel-based alloy with electroplated cubic boron nitride (CBN) wheels and straight oil is presented. These slots were prepared by this process for further grinding with electroplated CBN quills to generate the final fir-tree slots in gas turbine disks. Fir-tree slots are usually machined using broaching. The application of broaching, however, is limited in the case of nickel-based powder metal alloys due to short life of broaching tools and the effect on machined surface integrity. Grinding tests were first conducted on rectangular blocks to grind slots without inclinations at a fixed wheel speed v_s = 60 m/s to identify the combinations of depths of cut, workspeed, and up/down grinding satisfying the requirements of ground surface quality and material removal rate. Inclined slots were then ground with the identified condition on a block representing a segment of an actual turbine disk to validate the condition. The wheel life was finally tested by grinding all the slots on the actual disk. Grinding power was measured, and the ground surfaces were inspected for any sign of burning. Preset target material removal rate and wheel life were obtained. It was found that electroplated CBN wheels are capable of grinding deep profiled slots on the difficult-to-cut nickel-based alloy.

Abstract: In order to obtain a electroplated CBN cylindrical grinding wheel with ordered abrasive pattern, based on the phyllotaxis theory of biology, the cylindrical grinding wheel with phyllotactic pattern and its mask were designed, this wheel was fabricated with lithography mask electroplating technology, and also some problems on processes were investigated by experiments. The research results that the ordered abrasive pattern on cylindrical grinding wheel can be realized with the help of the phyllotaxis theory and lithography mask electroplating technology, which can give some references for making this kind of the engineered grinding wheel.

Abstract: Aiming at solving the problems of wheel loading in dry grinding of Carbon/Epoxy composite materials, a novel electroplated grinding wheel with controlled abrasive cluster was developed, in which the diameter of clusters is in Φ0.2 mm to Φ1.0 mm and the interspace between them is about 0.5 mm to 1.0 mm. A conventional electroplated grinding wheel with abrasive grains distributed randomly was fabricated in the same way. The comparison experiments involving C/E composite were conducted on a vertical spindle grinder with the novel and conventional grinding wheels. The results show that the grinding forces of novel wheel developed is more lower though little larger surface roughness, and the wheel loading phenomenon is markedly decreased compared with conventional electroplated wheel.