Experimental study on single grit grinding of Inconel 718

Abstract

This paper presents an important investigation of material removal mechanism in grinding utilizing single grit scratch tests. The investigation helps people to understand the abrasive cutting behaviour when the abrasive cutting edge shape alters during single grit grinding. The results provide fundamental knowledge of the grinding material removal process which helps to improve grinding performance and quality. CBN grits of 40/50 mesh size were used to perform scratch tests on the alloy Inconel 718. The concepts of material pile up ratio and material removal strength were introduced to measure the material removal efficiency during grinding. It is found that pile up ratio decreases and material removal strength increases when the depth of cut increases, albeit the material removal mechanism is highly dependent on the abrasive grit cutting edge shape. The material removal mechanism along the scratch length shows different behaviours at the entrance and exit sides of the scratching passes. When a grit was moving along its scratch path, it pushed material forward resulting in high material accumulation at the exit side of the scratches. Consequently, cutting is more prominent at the entrance side of the scratch, whereas ploughing or pile-up is extremely high at the exit side of the scratches. The research finding provides crucial information for grinding process optimization.

Analysis of Grinding Surface Creation by Single-Grit Approach

“…11, where the lower pile up ratio in that region suggest this fact. Although the material removal mechanism affected by the workpiece material mechanical property, similar trend was found with Inconel 718 workpiece material in [27]. FEM simulation results in Fig 12 also support the experiments, friction only affects the grit gouge depth in the first half of the scratch, whereas material pile up on the both sides of the scratches are increasing with addition of friction coefficient while the grit gouge depth is stable.…”

“…Knowledge about the cutting edges shapes and apex angle could give a valuable insight into the modelling the single grit action on the workpiece. Macro fracture of the grit could take place during the scratching process, which created multiple cutting edges resulting in multiple edge scratches[27]. Micro fractures took place on the grit cutting edges increases the cutting ability of the grit and improves the grit-workpiece engagement although which led to some tiny scratches within a main scratch groove[27].…”

“…Macro fracture of the grit could take place during the scratching process, which created multiple cutting edges resulting in multiple edge scratches[27]. Micro fractures took place on the grit cutting edges increases the cutting ability of the grit and improves the grit-workpiece engagement although which led to some tiny scratches within a main scratch groove[27]. These tiny scratches could play an important role in determination of final surface quality and surface finish.…”

Investigating the Sanding Process of Medium-Density Fiberboard and Korean Pine for Material Removal and Surface Creation

“…Rubbing occurs at the initial stage of grit-workpiece interaction at a very small region, and only elastic deformation is included [12]. Since rubbing is not easily observed due to the elastic spring back effect and the three stages (rubbing, ploughing, cutting) along a scratch vary in proportion and can even occur simultaneously [34], only a few experimental researches on rubbing can be found in grinding metal, alloy or other engineered materials.…”

Cutting Characteristics for Sugar Maple Using Single Grit with Spherical Cone and Triangular Pyramid Geometries

“…Rubbing accompanies material elastic deformation. Ploughing is initiated with an increasing grit penetration, which primarily leads to material plastic deformation and consumes energy without contributing much to material removal [5]. When the shearing strength reaches a critical stage, part of the deformed material is completely torn out, and debris is removed during grit cutting.…”