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CBN grain wear and its effects on material removal during grinding of FGH96 powder metallurgy superalloy

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Abstract

Grinding with cubic boron nitride (CBN) superabrasive is a widely used method of machining superalloy in aerospace industries. However, there are some issues, such as poor grinding quality and severe tool wear, in grinding of powder metallurgy superalloy FGH96. In addition, abrasive wheel wear is the significant factor that hinders the further application of CBN abrasive wheels. In this case, the experiment of grinding FGH96 with single CBN abrasive grain using different parameters was carried out. The wear characteristics of CBN abrasive grain were analyzed by experiment and simulation. The material removal behavior affected by CBN abrasive wear was also studied by discussing the pile-up ratio during grinding process. It shows that morphological characteristics of CBN abrasive grain and grinding infeed direction affect the CBN abrasive wear seriously by simulation analysis. Attrition wear, micro break, and macro fracture had an important impact on material removal characteristics. Besides, compared with the single cutting edge, higher pile-up ratio was obtained by multiple cutting edges, which reduced the removal efficiency of the material. Therefore, weakening multiple cutting edge grinding on abrasive grains in the industrial production, such as applying suitable dressing strategy, is an available method to improve the grinding quality and efficiency.

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Acknowledgement

This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 92160301, 52175415), Major Special Projects of Aero-engine and Gas Turbine (Grant No. 2017-VII-0002-0095), and Funding for Outstanding Doctoral Dissertation in NUAA (Grant No. BCXJ19-06).

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Authors and Affiliations

  1. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Ben-Kai Li, Biao Zhao, Wen-Feng Ding & Yu-Can Fu

  2. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, 266525, Shandong, People’s Republic of China

    Chang-He Li

  3. Aecc Xi’an Aero-engine Ltd, Xi’an, 710021, People’s Republic of China

    Rong Wang

  4. State Key Laboratory of Superabrasives, Zhengzhou Research Institute for Abrasive and Grinding, Zhengzhou, 450001, People’s Republic of China

    Yan-Jun Zhao

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  1. Ben-Kai Li
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  2. Biao Zhao
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  3. Wen-Feng Ding
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  4. Yu-Can Fu
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Correspondence to Wen-Feng Ding.

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Li, BK., Zhao, B., Ding, WF. et al. CBN grain wear and its effects on material removal during grinding of FGH96 powder metallurgy superalloy. Adv. Manuf. 11, 21–38 (2023). https://doi.org/10.1007/s40436-022-00412-2

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  • DOI: https://doi.org/10.1007/s40436-022-00412-2

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