19 The research of electroplated CBN grinding wheel for superallloy

The Research of Electroplated CBN Grinding Wheel for Superalloy

Superalloys are a class of high-performance alloys that exhibit exceptional mechanical strength, superior surface stability, and excellent resistance to corrosion and high temperatures. They are widely used in industries such as aerospace, power generation, and automotive due to their unique properties. However, machining superalloys can be a challenging task due to their high hardness and heat resistance. In recent years, the electroplated cubic boron nitride (CBN) grinding wheel has emerged as a promising tool for grinding superalloys. This article will explore the research and development of electroplated CBN grinding wheels for superalloy machining.

1. Introduction

Superalloys are extensively used in the manufacturing of gas turbines, aircraft engines, and other high-performance components. Machining these alloys is highly demanding due to their high melting point, low thermal conductivity, and high work hardening tendency. Traditional grinding techniques using conventional abrasive wheels often lead to excessive tool wear, limited material removal rate, and poor surface roughness. Therefore, there is a need for advanced grinding technologies to overcome these challenges and improve the efficiency and quality of superalloy machining.

2. Electroplated CBN Grinding Wheel

The electroplated CBN grinding wheel is a novel tool that has gained significant attention in the field of superalloy machining. It consists of a metal core, typically made of steel or aluminum, with a layer of electroplated CBN grains on its surface. The electroplating process ensures a strong bond between the CBN grains and the metal core, resulting in high grinding efficiency and long tool life. The CBN grains have exceptional hardness and thermal stability, allowing them to withstand the high temperatures generated during grinding without significant wear or deterioration.

The electroplated CBN grinding wheel offers several advantages over conventional grinding wheels. Firstly, its high hardness enables it to cut through superalloys with ease, reducing machining time and improving productivity. Secondly, the electroplating process allows for precise control over the distribution and size of the CBN grains, resulting in a more uniform and consistent cutting action. Lastly, the electroplated CBN grinding wheel generates less heat during grinding, reducing the risk of thermal damage to the workpiece and improving surface integrity.

3. Research and Development

Extensive research has been conducted to optimize the design and performance of electroplated CBN grinding wheels for superalloy machining. One area of focus is the selection of suitable metal cores for improved stability, heat dissipation, and vibration damping. Steel cores are commonly used due to their high stiffness, while aluminum cores offer better heat conductivity. Researchers have also explored the use of composite cores that combine the advantages of both materials.

Another aspect of research involves improving the electroplating process to achieve a strong bond between the CBN grains and the metal core. Factors such as bath composition, plating parameters, and post-treatment techniques have been investigated to enhance the adhesion and cohesion of the CBN layer. Additionally, studies have been conducted to optimize the CBN grain size, concentration, and distribution to achieve the desired cutting performance and surface quality.

Furthermore, researchers have explored various methods to enhance the cooling and lubrication capabilities of the electroplated CBN grinding wheel. Techniques such as wheel dressing, coolant application, and air jet cooling have been investigated to reduce the grinding temperature, prevent workpiece burn, and improve chip evacuation. These advancements aim to further improve the tool life, material removal rate, and surface finish during superalloy machining.

The research and development of electroplated CBN grinding wheels for superalloy machining have shown promising results. These innovative tools offer significant advantages over conventional grinding wheels, including higher efficiency, improved surface quality, and longer tool life. By optimizing the design, manufacturing process, and cooling/lubrication techniques, researchers are continuously improving the performance of electroplated CBN grinding wheels. As a result, machining superalloys is becoming more efficient and cost-effective, contributing to the advancement of various industries dependent on these exceptional materials.