Influence of Electroplated CBN Wheel Wear on Grinding Surface Morphology of Powder Metallurgy Superalloy FGH96

Abstract

The electroplated cubic boron nitride (CBN) wheel has perfect precision retention and high-temperature grinding performance, which is widely used in the field of grinding difficult-to-cut materials, such as nickel-based superalloy. However, the research on the influence law and mechanism of grinding surface morphology affected by the wear state of small-size grinding wheel is insufficient, which limits the further promotion and application of electroplated CBN wheel in the field of precision grinding of superalloy materials. Based on the in-depth analysis of the structure of FGH96 turbine disk, and combined with the actual processing requirements, the electroplated CBN wheel was designed, and the abrasive grains size selection experiments and CBN wheel wear experiments were then carried out for the powder metallurgy superalloy FGH96 in turn. The influence law of the abrasive grain size of CBN grinding wheel and the wear state of grinding wheel on the surface morphology was investigated, respectively. The obtained results showed that under the given processing parameters, the surface roughness Ra using 400# and 600# electroplated CBN wheels are around 0.66 μm and 0.53 μm during the normal wear state of grinding wheels, respectively, which can meet the requirement of surface quality less than Ra 0.8 μm in engineering application of turbine disk, and prove the feasibility of small-size CBN wheel grinding FGH96. In addition, the failure form of electroplated CBN wheel is mainly the accumulation and adhesion of abrasive debris, and the crushing and shedding of abrasive grain are hard to appear.

A brief review on the status of machining technology of fir-tree slots on aero-engine turbine disk

“…With the development of manufacturing technology of high-speed spindle and superabrasive electroplated grinding wheel, high-speed profiled grinding is gradually applied to the machining field of turbine disk slots. [54][55][56] Mantel developed a grinding method of slot by using superabrasive grinding wheel for the side rough grinding and profiled grinding wheel for the finish machining. 57 Meanwhile, the application verification of grinding Udimet 720 turbine disk slots by electroplated CBN and diamond grinding wheel was carried out.…”

A current review on boron nitride nanotubes and their applications

“…BN in particulate form has several applications in different fields, viz. lubricants [10], fillers [11], coatings [12], cutting tools [13], cosmetics [14], abrasives [15] and in semiconductor devices [16]. Hexagonal BN is structurally similar to graphene [17], hence is capable of forming nanotubes.…”

Analyses of Influence on Chromium Coating after Grinding from the View of Final Microstructure and Microhardness in the Surface Layer

“…Various abrasive materials are used to grind more difficult to machine materials, and extensive research is being conducted in this area, which, of course, affects the resulting surface and its quality in various ways, i.e., the surface integrity. For example, Ding et al [ 20 ] wrote about research of monolayer CBN superabrasive wheels application for grinding metallic materials and Wang et al [ 21 ] about influence of electroplated CBN wheel wear on powder metallurgy superalloy FGH96 grinding. The topic of grinding (machining) and influencing the ground material by various parameters are also dealt with by [ 22 ], when there was presented research about using low-temperature coolants in machining to enhance the durability of AISI 316L stainless steel or [ 23 ], when there was presented research about grinding of titanium alloy Ti6Al4V with silicon carbide grinding wheel.…”