High-speed high-efficient grinding of CMCs with structured grinding wheels

Paper in proceeding, 2018

Ceramic Matrix Composites (CMCs) are counted as new materials which their implantation is limited due to their high machining costs as a result of high grinding forces and tool wear. To overcome mentioned problems, modified grinding wheels, one macro-structured by segmenting and another micro-structured (half lasered structured and half non-structured) were used in this study. The grinding tests were carried out at different material removal rates and cutting speeds. The grinding forces, generated surface roughness, and induced residual stress by means of grinding with the structured and non-structured wheels were compared. Reduction in the static cutting edges via wheel structuring resulted in a better performance of the grinding wheel through the reduction of rubbing and ploughing regimes. The grinding forces were respectively 30% and 20% lower in the case of segmented wheel and laser-structured wheel in comparison with the conventional grinding. In addition, the tensile residual stress can be reduced as a negative output of the grinding process via structuring. Moreover, a high-speed high-efficient grinding of CMCs without presence of surface damage was achieved by optimizing the process parameters. The material removal rate can be elevated without changing the grinding forces with application of the structured wheel.