Impact of cross-helix texture scaling on grinding performance using resin-bonded CBN laser-textured wheels
摘要
Producing micro-textures on machining tools is a proven method to enhance performance. Among conventional grinding wheels (cGWs), cross-helix textures are particularly effective. However, the impact of scaling cross-helix textures on grinding performance remains unexplored. For the first time, this study investigates the effect of scaling cross-helix textures produced on resin-bonded cubic boron nitride (CBN) grinding wheels on their performance during the grinding of 390 Böhler steel. Textures were created using picosecond laser ablation at 6.6 J/cm2, producing groove widths of 35 µm (nGW) and 165 µm (wGW). Groove quality was evaluated using a novel, self-designed quantification method, ensuring consistent groove widths with 125 and 100 laser scans for nGW and wGW, respectively. Grinding trials showed that nGW and wGW reduced temperatures from 69 °C (cGW) to 57 °C and 55 °C, respectively. Normal grinding forces were reduced from 41.5 N (cGW) to 31.6 N and 30.8 N for nGW and wGW, respectively. The surface roughness (Sq) of the workpiece improved from 1.29 µm (cGW) to 1.09–1.25 µm (nGW, wGW). In endurance tests, removing 7167 mm3 of material, textured GW reduced CBN grit fragmentation and pull-out by 41%, extending wheel lifespan. The grinding mechanism for the textured grinding wheels involved an increased number of cutting edges and effective coolant and chip storage in the grooves, contributing to improved performance.
Graphical Abstract