TY - JOUR

T1 - Process limits in high-performance peel grinding of hardened steel components with coarse CBN grinding wheels

AU - Denkena, Berend

AU - Kroedel, Alexander

AU - Wilckens, Michael

N1 - Funding Information: Prof. Dr.-Ing. B. Denkena was responsible for funding acquisition and project administration and reviewed and edited the article together with Dr.-Ing. A. Krödel in the writing process. Dr.-Ing. A. Krödel supervised the project. M. Wilckens conducted the experiments, analysed the data and wrote the manuscript.

PY - 2022/6

Y1 - 2022/6

N2 - Recent developments in the production processes for cubic boron nitride (CBN) abrasive grains have led to commercially available grain sizes larger than lg > 300 µm. These superabrasive grains allow higher material removal rates during grinding of hardened steel components. Currently, these components are pre-machined by turning processes before being hardened and eventually finished by grinding. However, the turning process can be substituted by grinding with coarse CBN-grains since higher depths of cut are achievable when machining hardened components. This paper investigates the process behaviour of vitrified and electroplated grinding wheels with large grain sizes during the machining of hardened steel components. Process forces, wear behaviour and workpiece surface roughness are investigated for three different grain sizes, and the process limits of both bond types are examined. The investigations show that vitrified tools do not fully suit the demands for peel grinding process with high material removal rates since wear by bond breakage occurs. The electroplated tools on the other hand are capable of very high material removal rates. Their wear behaviour is characterized by clogging of the chip space if the process limit is reached. Even so, both tools outperform a standard hard-turning process in terms of process time by 74% and 94% respectively. This process time reduction in combination with the possibility to use the same (machine) tool to machine both soft and hard sections of a workpiece adds flexibility to current process chains.

AB - Recent developments in the production processes for cubic boron nitride (CBN) abrasive grains have led to commercially available grain sizes larger than lg > 300 µm. These superabrasive grains allow higher material removal rates during grinding of hardened steel components. Currently, these components are pre-machined by turning processes before being hardened and eventually finished by grinding. However, the turning process can be substituted by grinding with coarse CBN-grains since higher depths of cut are achievable when machining hardened components. This paper investigates the process behaviour of vitrified and electroplated grinding wheels with large grain sizes during the machining of hardened steel components. Process forces, wear behaviour and workpiece surface roughness are investigated for three different grain sizes, and the process limits of both bond types are examined. The investigations show that vitrified tools do not fully suit the demands for peel grinding process with high material removal rates since wear by bond breakage occurs. The electroplated tools on the other hand are capable of very high material removal rates. Their wear behaviour is characterized by clogging of the chip space if the process limit is reached. Even so, both tools outperform a standard hard-turning process in terms of process time by 74% and 94% respectively. This process time reduction in combination with the possibility to use the same (machine) tool to machine both soft and hard sections of a workpiece adds flexibility to current process chains.

KW - CBN

KW - Grinding

KW - High performance cutting

KW - Wear

UR - http://www.scopus.com/inward/record.url?scp=85127556108&partnerID=8YFLogxK

U2 - 10.21203/rs.3.rs-872931/v1

DO - 10.21203/rs.3.rs-872931/v1

M3 - Article

AN - SCOPUS:85127556108

VL - 120

SP - 6079

EP - 6090

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

SN - 0268-3768

IS - 9-10

ER -