A novel porous aggregated cBN (AcBN) wheel was prepared under high-temperature sintering processes to ensure the desired machining efficiency and quality of Ti-6Al-4V alloys. The designations of pore structures and AcBN grains within metallic grinding wheels operating at the high efficiency deep grinding processes were conducted. Variations of grinding forces and force ratio, grinding temperature, specific grinding energy along with grinding parameters, was carried out. In addition, characterization analyses of grain wear morphologies of wheel surface were then performed with vitrified monocrystalline cBN (McBN) wheels and porous AcBN wheels.Findings show that the employment of Ti-coated cBN particles contributes to the improvement of chemical bonding strength between grains and metallic matrix alloys inside AcBN grains. Compared with the severe grain wear of vitrified McBN wheels, porous AcBN wheels possess the excellent wear resistance ability and desired machining quality, owing to the abundant chip storage space and micro-fracture properties of cBN particles.
Ultrasonic vibration-assisted grinding (UVAG) is frequently prescribed as an effective technique to improve the grindability of difficult-to-cut materials, earning tremendous application opportunities in the industrial field. However, the traditional optimization of grinding parameters requires substantial experimental analyses and is prone to fall into a local optimum. In this study, a multiobjective particle swarm optimization (MOPSO) model for grinding forces and surface roughness is established on the basis of comparative experiments between UVAG and conventional grinding. Optimized process parameters are then used to conduct ultrasonic vibration-assisted profile grinding experiments. Results show that the tangential and normal grinding forces are reduced by 20.51% and 18.91%, respectively, and the ground surface roughness (Ra) is decreased by 9.47%. In addition, the sharpness of grinding wheels can be maintained for UVAG. A Pareto solution set with 15 noninferior solutions is obtained using the MOPSO algorithm, suggesting that the good surface roughness is realized using larger wheel speed and cutting depth and a smaller feed speed. Finally, forming workpieces with excellent shape accuracy and high surface quality, as well as optimized machining parameters, are achieved under the ultrasonic vibration-assisted profile grinding process.
A novel porous aggregated cBN (AcBN) wheel was prepared under high-temperature sintering processes to ensure the desired machining efficiency and quality of Ti–6Al–4V alloys. The designations of pore structures and AcBN grains within metallic grinding wheels operating at the high efficiency deep grinding processes were conducted. Variations of grinding forces and force ratio, grinding temperature, specific grinding energy along with grinding parameters, was carried out. In addition, characterization analyses of grain wear morphologies of wheel surface were then performed with vitrified monocrystalline cBN (McBN) wheels and porous AcBN wheels. Findings show that the employment of Ti-coated cBN particles contributes to the improvement of chemical bonding strength between grains and metallic matrix alloys inside AcBN grains. Compared with the severe grain wear of vitrified McBN wheels, porous AcBN wheels possess the excellent wear resistance ability and desired machining quality, owing to the abundant chip storage space and micro-fracture properties of cBN particles.
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