Improve the grinding performance of Inconel 718 superalloys by using an internal cooling wheel with a phyllotaxy of abrasive arrangement

In order to improve the high grinding temperature and low machining efficiency during the grinding process of nickel-based superalloy, an internal cooling wheel (ICW) with the abrasive arranged in phyllotaxy was prepared to improve machined surface integrity and reduce grinding temperatures. Firstly, two sizes of ICW were designed, and the influence of abrasive particle arrangement on grinding performance was studied using the finite element method. Secondly, based on computational fluid dynamics methods, the finite element model of the grinding zone was established, and the influence of the size of the grinding wheel and the arrangement of abrasive on the heat transfer performance and flow characteristics of the grinding fluid in the grinding zone were investigated. In a specific range, small diameter wheel (SDW) with phyllotaxy arrangement shows advantages in heat transfer performance and fluid flow compared to large diameter wheel (LDW). Finally, the grinding test of Inconel 718 superalloy was studied. The result shows that compared with the ordered arrangement, the LDW and SDW with phyllotaxy arrangement both obtained lower grinding temperatures, decreased by 20.83% and 22.86%, and smaller surface roughness values, decreased by 30.07% and 33.94%. The SDW with a larger distribution angle can obtain lower grinding temperature and slightly better workpiece surface integrity.