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Abstract
The present investigation was dedicated to elucidate abrasive-wear mechanisms during surface grinding of a titanium alloy (TC4)
and a nickel-based superalloy (K417) by using silicon carbide (SiC), alumina (Al2 O3 ), and cubic boron nitride (CBN) wheels. The
temperature at the wheelworkpiece contact zone was measured using a workpiecefoil thermocouple. SEM and EDS were used to
examine the morphological features of ground workpiece surfaces and worn wheel surfaces. It is shown that the grinding with either SiC or Al2 O3 is characterized by the high temperatures reached in the grinding zone since either of them is easily worn during
the grinding processes. Along with the presence of high temperatures, strong adhesion was found between the abrasives and workpieces, which might be attributed to the chemical bonding between the abrasives and workpieces at the elevated temperatures. The
increasing ductile deformation of both TC4 and K417 at the elevated temperatures may also be a factor. Therefore, the wear of SiC
or Al2 O3 is both chemical and physical. In the grinding with CBN wheels, however, the wear of abrasive grits is mainly physical
since CBN is more stable to higher temperatures. At extremely high temperatures, CBN was found to undergo dislodging prior to being gradually worn. In order to reduce the grinding temperatures, a segmented wheel was incorporated into the grinding with CBN
wheels.
2003 Elsevier Science B.V. All rights reserved.
Keywords: Abrasive wear; Grinding; Titanium alloy; Superalloy; Temperature
1. Introduction
Titanium alloys and superalloys are widely used in the
aerospace and defense industry owing to their favorable mechanical strength and resistance to surface degradation. Unfortunately, the unique physical and chemical properties that
make these alloys suitable for many applications also contribute to the difficulty with which they are cut or ground.
During grinding using abrasive wheels, which has been one
of the most popular processes for titanium alloys and superalloys, short wheel life and severe surface abuse of ground
workpiece are the most important among the factors impairing their grindability.
Although extensive research has been conducted on the
grinding of superalloys and titanium alloys over the past
30 years with a specialization in the thermal damage to the
workpiece [14], relatively fewer studies have been dedicated to identify the mechanisms of abrasive wear. It was
previously mentioned that there might exist the possibility
of a chemically assisted wear process in grinding of titanium alloys or superalloys [1,4], however, no temperature
data was provided.
As one of the most commonly used titanium alloys, TC4
(Ti6Al4V) has an alphabeta structure and is widely used
for aircraft components. Among the commercially available superalloys used in the aeronautical industry, K417
(Ni15.2Co8.79Cr5.5Al4.9Ti3.23Mo) is a relatively
new nickel-base cast superalloy designed especially as turbine vane materials. In order to provide a technological
basis for optimizing the grinding of these two alloys, the
present investigation was undertaken to elucidate the mechanisms of abrasive wear during grinding of them using
three different abrasives wheels: Al2 O3 (for K417), SiC (for
TC4), and CBN (for both K417 and TC4). Temperatures
at the wheelworkpiece contact surface were measured
in the grinding processes to provide direct evidence for
mechanism analysis.
2. Experimental
0043-1648/03/$ see front matter 2003 Elsevier Science B.V. All rights reserved.
doi:10.1016/S0043-1648(03)00163-7
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X. Xu et al. / Wear 255 (2003) 14211426
Fig. 2. SEM pictures of the K417 surfaces ground with Al2 O3 and CBN
wheels: (a) Al2 O3 grinding when grinding temperature is 90 C; (b)
Al2 O3 grinding when grinding temperature is 1000 C; (c) CBN grinding
when grinding temperature is 70 C; (d) CBN grinding when grinding
temperature is 1000 C.
3. Results
3.1. Morphological features of ground K417 surfaces and
worn wheel surfaces
Fig. 2 shows SEM pictures of the ground K417 surfaces
generated by either Al2 O3 or CBN wheels. It can be seen
that the ground surfaces, which underwent different grinding temperatures, are featured with different topographies.
When the grinding temperature is around 90 C, which is below the critical threshold temperature for film boiling [7], the
ground surfaces for either Al2 O3 or CBN grinding are relatively smooth. The surfaces consist mostly of overlapping
scratches produced by the interactions of abrasive cutting
points with the workpiece (see Fig. 2a and c). However, the
morphologies of the workpiece surfaces ground with Al2 O3
become more complicated when the surface temperature is
up to 1000 C, in which case some kind of plastically deformed coatings prevail on the workpiece surfaces as indicated in Fig. 2b. As compared to Al2 O3 grinding, the coatings on the workpiece surfaces for CBN grinding are much
less even though the grinding temperature is up to 1000 C
(see Fig. 2d).
Fig. 3 shows the micro-observations made on the worn
surfaces of the Al2 O3 wheel, also indicating the effects of
grinding temperatures. When the temperatures on the workpiece surfaces are 70 or 90 C, either Al2 O3 or CBN appears
to be sharp as newly dressed (see Fig. 3a and c). However,
adhering materials can be found on Al2 O3 grits when the
temperature is up to 1000 C (see Fig. 3b). EDS analysis
of the adhering materials showed that there was no difference in chemical compositions between the adhering layers
and K417. Unlike Al2 O3 grits, no workpiece materials directly adhere to CBN grits even when grinding temperature
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X. Xu et al. / Wear 255 (2003) 14211426
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Fig. 3. SEM pictures for the worn surfaces of Al2 O3 and CBN wheels:
(a) Al2 O3 wheel when grinding temperature is 90 C; (b) Al2 O3 wheel
when grinding temperature is 1000 C; (c) CBN wheel when temperature
is 70 C; (d) CBN wheel when temperature is 1000 C; (e) heat induced
holes on CBN wheel.
Fig. 4. SEM pictures of TC4 surfaces ground with SiC and CBN wheels:
(a) SiC grinding when temperature is 100 C; (b) SiC grinding when
temperature is 500 C; (c) SiC grinding when temperature is 1000 C;
(d) CBN grinding when temperature is 80 C; (e) CBN grinding when
temperature is 600 C; (f) CBN grinding when temperature is 1300 C.
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X. Xu et al. / Wear 255 (2003) 14211426
(1)
Fig. 5. SEM pictures for the worn surfaces of SiC and CBN wheels: (a)
newly dressed SiC wheel; (b) SiC grinding when temperature is 1000 C;
(c) EDS data on the adhering materials in (b); (d) newly dressed CBN
wheel; (e) CBN grinding when temperature is 1300 C; (f) heat induced
holes on CBN wheel.
(2)
(3)
(4)
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X. Xu et al. / Wear 255 (2003) 14211426
plastically deformed coating on the workpiece ground surface. Along with the dislodging of adhering layers from an
abrasive grit, adhesive wear may occur at the abrasive grit
by a mechanism similar to the formation of scars on the
workpiece.
Aside from chemical activity, purely mechanical factors
also contribute significantly to the adhesion between the
abrasive and workpieces. Actually, metals which are more
adhesive, such as titanium and nickel-base alloys, tend to
exhibit more ductility at elevated temperatures, thereby leading to possible cold-welding between the abrasive grits and
workpiece materials. Therefore, the plastically deformed
coatings on the ground workpiece surfaces and the adhering
materials on the worn abrasive grits should be attributed to
the combining effect of the chemical interactions and the increasing amount of ductile deformation at elevated grinding
temperatures.
Compared with Al2 O3 and SiC, CBN is more chemically stable to higher temperatures. Although some studies
suggested a possible chemical interaction that may occur
with CBN at very high temperatures, the kinetics of the
reaction must be considered because the oxidation of CBN
is a timetemperature reaction. Actually, a CBN grit is
heated only during its contact with the workpiece and the
heat flowing into the grit is extracted during the remaining
portion of a single revolution of the grinding wheel. The
fact that much fewer workpiece materials purely physically adhering to the CBN wheels seems to indicate that
chemical activity is at least not the dominant factor in
the CBN grinding. Therefore, the much fewer plastically
deformed coatings on the ground workpiece surfaces as
shown in Figs. 2d and 4e should be mainly attributed to the
enhancement of plastic deformation at elevated temperatures.
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X. Xu et al. / Wear 255 (2003) 14211426
6. Conclusions
Acknowledgements
The present work was supported by the Natural Science
Foundation (NSF) of Fujian Province in China, by the Special Funds from Huaqiao University for Selected Faculty
Members Holding Ph.D., and partially by the Aeronautical
Science Foundation of China.
References