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Review on Monolayer CBN Superabrasive Wheels for Grinding Metallic Materials, Chin J Aeronaut (2016)

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Review on Monolayer CBN Superabrasive Wheels for Grinding Metallic Materials, Chin J Aeronaut (2016) CJA 694 No. of Pages 27 25 October 2016 Chinese Journal of Aeronautics, (2016), xxx(xx): xxx–xxx 1 Chinese Society of Aeronautics and Astronautics & Beihang University Chinese Journal of Aeronautics [email protected] www.sciencedirect.com 2 REVIEW ARTICLE 4 Review on monolayer CBN superabrasive wheels 5 for grinding metallic materials a,* b a a a 6 Wenfeng Ding , Barbara Linke , Yejun Zhu , Zheng Li , Yucan Fu , a a 7 Honghua Su , Jiuhua Xu a 8 College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China b 9 Department of Mechanical and Aerospace Engineering, University of California Davis, Davis, CA 95616, USA 10 Received 7 April 2016; revised 23 May 2016; accepted 2 July 2016 11 13 KEYWORDS 14 Abstract A state-of-the-art review on monolayer electroplated and brazed cubic boron nitride 15 Brazed; (CBN) superabrasive wheels for grinding metallic materials has been provided in this article. The 16 Cubic boron nitride; fabrication techniques and mechanisms of the monolayer CBN wheels are discussed. Grain distri- 17 Electroplated; bution, wheel dressing, wear behavior, and wheel performance are analyzed in detail. Sample appli- 18 Grinding; cations of monolayer CBN wheel for grinding steels, titanium alloys, and nickel-based superalloys 19 Monolayer superabrasive are also provided. Finally, this article highlights opportunities for further investigation of mono- 20 wheels layer CBN grinding wheels. 21 Ó 2016 Chinese Society of Aeronautics and Astronautics. Production and hosting by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). 22 1. Introduction advantages, some of which include good form retention over 31 long grinding times, capability of running at higher removal 32 23 Monolayer cubic boron nitride (CBN) wheels, including elec- rates (due to high grain protrusion and large chip-storage 33 6–11 24 troplated wheels and brazed wheels, are usually fabricated with spaces ), reduction of the complex pre-grinding wheel 34 25 a single layer of superabrasive grains that are bonded to a preparation work (i.e., periodically dressing and truing opera- 35 26 metallic wheel substrate by an electroplated nickel layer or a tions especially in rough grinding), and possible re-application 36 1,2 3 27 brazed filler layer, as schematically displayed in Fig. 1. In of the wheel hub after the grains wear out (such as stripping of 37 4,5 12,13 28 comparison to the multi-layered CBN wheel types, i.e., the abrasive layer). 38 29 resin-bonded wheels, vitrified-bonded wheels and metallic- In particular, the CBN wheels for high-speed grinding and 39 30 bonded wheels, monolayer CBN wheels have significant high-efficiency grinding are usually subject to special require- 40 ment regarding resistance to fracture and wear; at the same 41 * Corresponding author. time, good damping characteristics, high rigidity, and good 42 7 E-mail addresses: [email protected] (W. Ding), bslinke@ thermal conductivity are also desirable. Under such condi- 43 ucdavis.edu (B. Linke). tions, the grinding wheels are normally required to be com- 44 Peer review under responsibility of Editorial Committee of CJA. posed of a body with high mechanical strength and a 45 comparably thin coating of CBN superabrasives attached to 46 the body using a high-strength adhesive. The highest cutting 47 Production and hosting by Elsevier http://dx.doi.org/10.1016/j.cja.2016.07.003 1000-9361 Ó 2016 Chinese Society of Aeronautics and Astronautics. Production and hosting by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Please cite this article in press as: Ding W et al. Review on monolayer CBN superabrasive wheels for grinding metallic materials, Chin J Aeronaut (2016), http://dx.doi. org/10.1016/j.cja.2016.07.003 CJA 694 No. of Pages 27 25 October 2016 2 W. Ding et al. Fig. 1 Schematics of monolayer electroplated and brazed CBN wheels.3 48 speed is only achievable with monolayer CBN wheels, as CBN superabrasive grains must be taken into consideration 75 14 49 demonstrated in Fig. 2. when designing the particular concave and convex asperities 76 19 50 To utilize the advantages of high-speed grinding, in the past on the circumferential surface of the metallic wheel hub. 77 51 decades, the monolayer CBN wheels have been applied more The reason is due to the fact that the final profile dimension 78 52 and more in grinding of some important metallic structure of the monolayer CBN wheel is completely determined by both 79 53 materials (i.e., steels, titanium alloys and nickel-based superal- the wheel hub and the grain size, as schematically shown in 80 15–17 20 54 loys) in the automobile and aerospace industries. Fig. 4. If either wheel hub or grain size distribution exceeds 81 55 This article aims to provide a state-of-the-art review on the desired tolerances, the profile dimension accuracy of the 82 56 monolayer CBN wheels for grinding metallic materials, and ground components will not meet the desired level. For mono- 83 57 to offer the authors’ viewpoint about some further investiga- layer wheels, preparing the wheel hub with high strength and 84 58 tion. For an easy understanding of the relationship between high accuracy is not as decisive for the wheel performance as 85 59 fabrication techniques, grain distribution, dressing techniques, the proper bonding of the CBN grains to the wheel hub. For 86 60 tool wear, grinding simulation, and application techniques, a this reason, this section will focus on the bonding techniques 87 61 summarized diagram is firstly demonstrated in Fig. 3. rather than wheel hub preparation. 88 Usually, the metallic bonds of the monolayer CBN wheels 89 62 2. Fabrication of monolayer CBN superabrasive wheels are primarily produced by electroplating and brazing; mean- 90 while, the electroless plating process is also reported infre- 91 4 quently. Figs. 5 and 6 display the sample morphology and 92 63 The electroplated CBN wheels and brazed counterparts are grain protrusion of monolayer electroplated and brazed 93 64 both composed of metallic wheel hub, bonding layer and 3 CBN grinding wheels, respectively. 94 65 CBN superabrasive grains, as displayed in Fig. 1. The applied 66 metallic material of wheel hub mainly includes AISI 1020 steel, 2.1. Fabrication mechanism of monolayer electroplated CBN 95 67 AISI 1045 steel, alloyed steel, and hardened ball bearing steel 18 wheels 96 68 (100Cr6) ; surely, if the application does not allow for a mag- 69 netic material, aluminum or bronze/brass may be also uti- 4 97 70 lized. Furthermore, the structure design and mechanical 2.1.1. Bonding of CBN grains based on the traditional 98 71 machining of the wheel hub are always carried out according electroplating technique 72 to the comprehensive requirements of the machine tools and In most cases, nickel is utilized as the bond material between 99 73 component profiles. Particularly, for the profile grinding of CBN grains and metallic substrate of the monolayer electro- 100 74 some critical components (i.e., aero-engine blade), the size of plated wheels. The traditional electroplating technique is based 101 on the cathodic metal deposition behavior from a watery elec- 102 4 trolyte. Generally, fabrication of electroplated CBN wheels 103 23 may be described as follows : pretreatment of metallic wheel 104 hub and CBN grains before electroplating; preparation of elec- 105 troplating solution; spreading and plating the CBN grains on 106 the wheel working surface and then thickening the bond 107 material. 108 During electroplating, the anode consists of the bonding 109 material and the wheel hub acts as cathode. The wheel hub 110 is completely covered with CBN grains and placed into the 111 electrolytic bath. Particularly, the area to be coated is required 112 to be surrounded by a sufficient amount of grains. The elec- 113 trolytic bath consists of a watery solution of metal salts from 114 4 the deposited metal, such as Ag, Co, Cu, Ni, Au salts. The 115 direct current voltage leads to precipitation of Ni at the wheel 116 Fig. 2 Affordable grinding speeds and materials removal rates hub. After the initial bonding of the grains, the excessive grains 117 of different CBN wheels.14 Please cite this article in press as: Ding W et al. Review on monolayer CBN superabrasive wheels for grinding metallic materials, Chin J Aeronaut (2016), http://dx.doi. org/10.1016/j.cja.2016.07.003 CJA 694 No. of Pages 27 25 October 2016 Review on monolayer CBN superabrasive wheels for grinding metallic materials 3 Fig. 3 An overview of the current review work on monolayer CBN superabrasive wheels for grinding metallic materials. 15 Fig. 7. Particularly, the stripping of nickel bond from the 132 wheel hub also becomes a common phenomenon and major 133 deciding factor for shortening the tool service life. In order 134 to improve the bonding strength between the nickel bond 135 and the metallic wheel hub, and finally raise the service life 136 of the electroplated CBN wheels, measures such as heat- 137 diffusion treatment and coating have been applied. 138 2.1.2. Fe-rich electrodeposition and heat-diffusion treatment 139 As for the conventional electrodeposition, the Fe-content of 140 the electroplating solution must be reduced to the minimum 141 because it could affect the brittleness of the deposited layer. 142 On the contrary, in the research work carried out by 143 23 Liu et al. , Fe-atoms was creatively used by means of 144 FeSO Á7H O in the electroplating solution.
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