Grinding with Cubic Boron Nitride (CBN) Electroplated Wheels

这项拨款为研究电镀立方氮化硼（CBN）车轮的磨削过程提供了资金。这些车轮是由一层CBN超磨料颗粒制成的，通过电镀镍结合在轮毂表面。在磨削开始时，从电镀镍结合剂中突出的锋利的超磨粒尖随着持续使用逐渐变钝，从而导致在整个车轮寿命期间力逐渐增加，表面粗糙度相应降低。本研究的目的是表征砂轮磨损及其影响的主要机制的磨削过程在整个车轮寿命。研究包括：(1)表征新的（未使用的）车轮形貌；(2)通过实验测量和建模，研究车轮磨损对车轮表面形貌的影响及其对车轮寿命期间力、功率和表面粗糙度的影响；(3)研究了磨削温度计算和热损伤预测的能量分配。将开发定量模型来预测车轮形貌、车轮磨损、磨削力和能量、表面粗糙度、车轮寿命、磨削温度和热损伤。电镀CBN砂轮被广泛应用于精密金属部件的生产，特别是在航空航天和汽车工业中。虽然人们已经做出了巨大的努力来制造更好的电镀超磨料砂轮，但几乎没有关于这些砂轮磨削行为的基础研究报告。研究结果将为预测和模拟磨削行为、磨削周期设计和工艺优化控制提供分析依据。因此，它将通过提供所需的信息来自信地指定特定生产应用的最佳工艺参数，从而支持电镀CBN车轮的有效利用。

This grant provides funding to investigate the grinding process with electroplated cubic boron nitride (CBN) wheels. These wheels are manufactured with a single layer of CBN superabrasive grains held on the wheel hub surface by an electroplated nickel bond. The sharp superabrasive grain tips protruding from the electroplated nickel binder at the start of grinding progressively dull down with continued use, thereby resulting in a progressive increase in the forces and a corresponding decrease in the surface roughness throughout the wheel life. This investigation is aimed at characterizing the wheel wear and its effects on the prevailing mechanisms of the grinding process throughout the wheel life. The research encompasses: (1) characterization of the new (unused) wheel topography; (2) experimental measurement and modeling of how the wheel topography changes due to wheel wear and its effect on the forces, power, and surface roughness during the wheel life; and (3) investigation of the energy partition for calculating grinding temperatures and predicting thermal damage. Quantitative models will be developed to predict the wheel topography, wheel wear, grinding forces and energy, surface roughness, wheel life, grinding temperatures, and thermal damage. Electroplated CBN abrasive wheels are becoming widely used in the production of precision metallic components especially in the aerospace and automotive industries. While significant efforts have been directed towards making better electroplated superabrasive wheels, virtually no fundamental research has been reported concerning the grinding behavior with these wheels. The results of the present investigation will provide the analytical basis for predicting and simulating grinding behavior, design of grinding cycles, and optimal control of the process. As such, it will support the efficient utilization of electroplated CBN wheels by providing the information needed to confidently specify the optimal process parameters for a specific production application.