Article: Grinding characteristics of a nickel-based alloy using vitrified CBN wheels Journal: International Journal of Abrasive Technology (IJAT) 2012 Vol.5 No.1 pp.1 - 16 Abstract: An experimental study is reported on the grinding of a nickel-based alloy using vitrified CBN wheels. This work was motivated by switching the grinding of fir-tree root forms of jet engine blades from creep-feed grinding with conventional abrasive wheels to vitrified CBN wheels. The objective is to explore process limits and practical grinding parameters for judging the switch in terms of overall costs and productivity. Straight surface grinding experiments were conducted with water-based fluid on rectangular blocks at a fixed wheel speed vs = 45 m/s, various depths of cut a = 0.05-1.0 mm, and workspeeds vw = 2-40 mm/s. Grinding and dressing power, forces, surface roughness, and radial wheel wear were measured. Specific material removal rate of 8 mm³/(mm.s) was reached in rough grinding using a wheel dressed for achieving surface roughness Ra = 0.8 µm in finish grinding. It was found that shallow depths of cut combined with fast workspeeds, or less creep-feed modes, are more suitable for achieving high material removal rates with vitrified CBN grinding. Rough grinding is restricted by high grinding temperatures with newly dressed wheels and by chatters with worn wheels. Inderscience Publishers - linking academia, business and industry through research

Title: Grinding characteristics of a nickel-based alloy using vitrified CBN wheels

Authors: Zhongde Shi; Amr Elfizy; Benoit St-Pierre; Helmi Attia

Addresses: Aerospace Manufacturing Technology Centre, Institute for Aerospace Research of National Research Council Canada, 5145 Avenue Decelles, Montreal, Quebec, H3T 2B2, Canada. ' Manufacturing Engineering Development, Pratt and Whitney Canada, 1000 Marie-victorin, Longueuil, Quebec, J4G 1A1, Canada. ' Manufacturing Engineering Development, Pratt and Whitney Canada, 1000 Marie-victorin, Longueuil, Quebec, J4G 1A1, Canada. ' Aerospace Manufacturing Technology Centre, Institute for Aerospace Research of National Research Council Canada, 5145 Avenue Decelles, Montreal, Quebec, H3T 2B2, Canada

Abstract: An experimental study is reported on the grinding of a nickel-based alloy using vitrified CBN wheels. This work was motivated by switching the grinding of fir-tree root forms of jet engine blades from creep-feed grinding with conventional abrasive wheels to vitrified CBN wheels. The objective is to explore process limits and practical grinding parameters for judging the switch in terms of overall costs and productivity. Straight surface grinding experiments were conducted with water-based fluid on rectangular blocks at a fixed wheel speed v_s = 45 m/s, various depths of cut a = 0.05-1.0 mm, and workspeeds v_w = 2-40 mm/s. Grinding and dressing power, forces, surface roughness, and radial wheel wear were measured. Specific material removal rate of 8 mm³/(mm.s) was reached in rough grinding using a wheel dressed for achieving surface roughness R_a = 0.8 µm in finish grinding. It was found that shallow depths of cut combined with fast workspeeds, or less creep-feed modes, are more suitable for achieving high material removal rates with vitrified CBN grinding. Rough grinding is restricted by high grinding temperatures with newly dressed wheels and by chatters with worn wheels.

Keywords: vitrified CBN grinding wheels; wheel dressing; nickel-based alloys; grinding power; grinding forces; surface roughness; G-ratio; fir tree root forms; jet engine blades; radial wheel wear; material removal rate; MRR; grinding temperature.

DOI: 10.1504/IJAT.2012.046827

International Journal of Abrasive Technology, 2012 Vol.5 No.1, pp.1 - 16

Received: 18 Nov 2011
Accepted: 10 Feb 2012
Published online: 30 Jul 2014 *

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Title: Grinding characteristics of a nickel-based alloy using vitrified CBN wheels

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