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

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Abstract

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.

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Funding

The present research work was sponsored by the National Natural Science Foundation of China (Grant Nos. 52275405, 52275311, 51875050), the Hunan Province Science and Technology Innovation Program (Grant No. 2023RC1078), and the Changsha City Science and Technology Innovation Program (Grant No. kh2301003).

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Authors and Affiliations

  1. Hunan Provincial Key Laboratory of Intelligent Manufacturing Technology for High-Performance Mechanical Equipment, Changsha University of Science and Technology, Changsha, 410114, China

    Cong Mao, Xiang Li, Mingjun Zhang, Jian Zhang, Yuanqiang Luo, Weidong Tang, Kun Tang & Yongle Hu

  2. China Railway Wuxin Heavy Industry Co., Ltd., Changsha, 410199, China

    Weiyou Zhang

  3. Department of Civil and Mechanical Engineering, Purdue University Fort Wayne, Fort Wayne, IN, 46805, USA

    Zhuming Bi

  4. School of Mechanical and Electrical Engineering, Putian University, Putian, 351100, China

    Zhenheng Lin

Authors
  1. Cong Mao
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  2. Xiang Li
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  3. Mingjun Zhang
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  4. Jian Zhang
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  5. Weiyou Zhang
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  6. Yuanqiang Luo
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  7. Weidong Tang
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  8. Kun Tang
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  9. Zhuming Bi
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  10. Yongle Hu
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  11. Zhenheng Lin
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by C.M. and X.L. The first draft of the manuscript was written by C.M. and X.L., and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Mingjun Zhang.

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Mao, C., Li, X., Zhang, M. et al. Wear behaviors of electroplated CBN grinding wheel with orderly-micro-grooves in grinding narrow-deep slot. Int J Adv Manuf Technol 131, 2857–2868 (2024). https://doi.org/10.1007/s00170-023-12509-4

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