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Structure design and experimental study on ultrasonic vibration–assisted induction brazing cubic boron nitride abrasive tools

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Abstract

Brazed superabrasive tool has been widely used in machining of difficult-to-cut materials to improve the machining efficiency and quality. However, the severe wear and associated short service life have to be faced for conventional induction brazed (CIB) abrasive tools during machining processes, owing to its weak bonding strength between abrasive grains and metal-bonded phases. In this case, the method of ultrasonic vibration–assisted induction brazing (UVAIB) was proposed to fabricate tools, through introducing ultrasonic vibration into brazing process to improve the abrasive bonding strength. Here, a novel UVAIB device was developed, and the geometric designation parameters were optimized using a finite element simulating method. In addition, the performance of UVAIB device was tested in terms of the impedance and amplitude. Subsequently, the comparative experiment trials were performed with the brazed abrasive tools under the CIB and UVAIB method. Results show that the ultrasonic energy loss of UVAIB device can be reduced, and then, the amplification value and vibration uniformity reach 8 and 92%, respectively. In addition, a large number of pores and macro-cracks inside tool’s metallic matrix for CIB can be observed, whereas the number of pores is reduced by 75%, and only fewer and smaller micro-cracks are found for UVAIB. Furthermore, compared with the grains’ intergranular fracture for CIB, UVAIB exhibits the transgranular fracture mode due to its higher bonding strength after adopting the ultrasonic vibrating method.

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Funding

This work was financially supported by the National Natural Science Foundation of China (Nos. 51921003, 92160301, 52175415, and 52205475), Natural Science Foundation of Jiangsu Province (No. BK20210295), Superior Postdoctoral Project of Jiangsu Province (No. 2022ZB215), the Open Foundation State Key Laboratory of Mechanical Transmissions (No. SKLMT-MSKFKT-202101), the Postgraduate Research & Practice Innovation Program of Jiangsu Province (No. SJCX21-0106), and the Special Projects for the Reengineering of Industrial Foundation and the High-quality Development of Manufacturing Industry (No. TC210H02X).

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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, China

    Kaida Cai, Biao Zhao, Bangfu Wu & Wenfeng Ding

  2. State Key Laboratory of Superabrasives, Zhengzhou Research Institute for Abrasive & Grinding, Zhengzhou, 450001, China

    Yanjun Zhao & Jianhui Zhu

  3. Suzhou Far-East Abrasives Co., LTD, Suzhou, 215151, China

    Wenyuan Si

Authors
  1. Kaida Cai
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  2. Biao Zhao
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  3. Bangfu Wu
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  4. Wenfeng Ding
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  5. Yanjun Zhao
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  6. Jianhui Zhu
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  7. Wenyuan Si
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Contributions

Kaida Cai: experimentation, data curation, and writing the original draft. Biao Zhao: data collection and manuscript revision. Bangfu Wu: experimentation and methodology. Wenfeng Ding: supervision, conceptualization, and methodology.

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Correspondence to Biao Zhao.

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Cai, K., Zhao, B., Wu, B. et al. Structure design and experimental study on ultrasonic vibration–assisted induction brazing cubic boron nitride abrasive tools. Int J Adv Manuf Technol 123, 943–955 (2022). https://doi.org/10.1007/s00170-022-10231-1

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