Abstract Single-layer electroplated cBN wheels offer several advantages over conventional wheels when grinding difficult-to-cut materials, in terms of improved workpiece surface integrity issues, such as lower grinding burn, fewer surface defects, and generation of compressive residual stresses. However, grinding behaviour e.g., grinding forces, temperature, and surface integrity, changes with wheel use while employing single-layer wheels due to progressive wheel wear as dressing is not conducted for them. Therefore, wheel wear and associated grindability studies like grinding forces and surface integrity are essential for the implementation of these wheels in the industry. The present study evaluates the wear mechanism of the electroplated cBN wheel and its effect on the grindability of Ti–6Al–4V. High grinding speeds (40 & 60 m/s) were employed under different cutting fluids environments (water-based soluble oil emulsion in minimum quantity cooling lubrication (MQCL) as well as in flood cooling modes and neat oil in MQCL regime). A lower cutting speed of 20 m/s is also chosen for benchmarking purpose. Grit fracture is found to be the primary mode of wheel wear. An elaborate discussion on the mechanism of cBN grit fracture is presented. It is observed that thermal shock-induced fracture has a dominant effect on wheel wear, and consequently, water-based fluid provided 2–4 times higher radial wear than neat oil up to 40 m/s. Because of lower radial wear, neat oil provided only 0–10% increase in grinding forces, 0–10% decrease in compressive residual stress, and almost the same level of surface redeposition with the progression of cumulative material removal. On the other hand, water-based fluid yielded 30–100% rise in grinding forces, 10–75% decrease in compressive residual stress, and a higher level of surface redeposition.

中文翻译：

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钛合金高速超硬磨料磨削磨损机理及其对表面完整性的影响

摘要 在磨削难切削材料时，单层电镀 cBN 砂轮比传统砂轮具有多种优势，在改善工件表面完整性问题方面，如较低的磨削烧伤、较少的表面缺陷和产生压缩残余应力。然而，磨削行为，例如磨削力、温度和表面完整性，在使用单层砂轮时会随着砂轮的使用而变化，因为砂轮逐渐磨损，因为没有对其进行修整。因此，砂轮磨损和相关的可磨性研究（如磨削力和表面完整性）对于在行业中实施这些砂轮至关重要。本研究评估了电镀 cBN 砂轮的磨损机制及其对 Ti-6Al-4V 可磨性的影响。高研磨速度（40 & 60 m/s) 在不同的切削液环境下（微量冷却润滑 (MQCL) 中的水基可溶性油乳液以及淹没冷却模式和 MQCL 状态下的纯油）。还选择了 20 m/s 的较低切割速度用于基准测试。发现砂粒断裂是车轮磨损的主要方式。详细讨论了 cBN 磨粒断裂的机制。据观察，热冲击引起的断裂对车轮磨损有主要影响，因此，水基流体提供的径向磨损比纯油高 2-4 倍，高达 40 m/s。由于较低的径向磨损，纯油仅使磨削力增加 0-10%，压缩残余应力降低 0-10%，并且随着累积材料去除的进展，表面再沉积几乎相同水平。