Grinding with Cubic Boron Nitride (CBN) Electroplated Wheels

该补助金提供资金用于研究电镀立方氮化硼（CBN）砂轮的磨削工艺。 这些车轮是由一个单一的CBN超级磨料颗粒层通过电镀镍结合剂保持在轮毂表面制造的。 在磨削开始时从电镀镍粘结剂突出的锋利的超级磨粒尖端随着继续使用而逐渐变钝，从而导致在整个砂轮寿命期间力的逐渐增加和表面粗糙度的相应降低。 这项调查的目的是表征砂轮磨损及其对整个砂轮寿命的磨削过程的主要机制的影响。 该研究包括：（1）表征新的（未使用的）砂轮形貌;（2）实验测量和建模砂轮形貌如何由于砂轮磨损而变化以及其在砂轮寿命期间对力、功率和表面粗糙度的影响;以及（3）研究用于计算磨削温度和预测热损伤的能量分配。 将开发定量模型来预测砂轮形貌、砂轮磨损、磨削力和能量、表面粗糙度、砂轮寿命、磨削温度和热损伤。 电镀CBN砂轮在精密金属部件的生产中得到了广泛的应用，特别是在航空航天和汽车工业中。 尽管人们已经做出了很大的努力来制造更好的电镀超硬磨料砂轮，但几乎没有关于这些砂轮磨削行为的基础研究报道。研究结果将为预测和模拟磨削行为、磨削循环设计和过程优化控制提供分析依据。 因此，它将通过提供所需的信息来支持电镀CBN砂轮的有效利用，从而为特定的生产应用确定最佳工艺参数。

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.