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<p>This study develops a thermo-fluid coupled simulation model to investigate the effects of ultrasonic vibration and substrate preheating on the molten pool behavior and cladding quality in the fabrication of CBN/CuSnTi composite grinding wheels via laser cladding. The model incorporates time-dependent thermophysical properties of a 45# steel substrate and CuSn18Ti9 binder, considering ultrasonic action, substrate temperature, and the Marangoni effect. Four typical process conditions were compared. At room temperature without ultrasound, the molten pool exhibited unidirectional heat flow, weak recirculation, and coarse grains. Introducing ultrasound reduced initial conductive heat flux by 2.19%, shifted the recirculation vortex center downward by 7.8%, and slightly improved grain refinement via enhanced surface tension gradients, but did not break the dominant heat flow pattern. Substrate preheating to 573.15&#xa0;K alone increased Marangoni convection strength and expanded surface flow, improving pool morphology and grain uniformity while weakening directional solidification. When ultrasound was further applied under preheating, the vortex center dropped 11.96%, peak velocity increased by 1.6 times, and the heat flow became more isotropic, lowering cooling and solidification rates and significantly improving structural compactness. Molten pool height, depth, and width increased by 8.13%, 10.7%, and 0.9%, respectively. These findings clarify the synergistic mechanism of thermal and acoustic effects and offer guidance for parameter optimization in high-performance grinding wheel fabrication.</p>

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Simulation and experimental study of ultrasonically assisted laser cladding for CBN/CuSn18Ti9 grinding wheels

  • 期刊论文

  • 发表日期：

    2025年8月16日

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  • Yamin Li,
  • Zhibo Yang,
  • Quanbin Zhang,
  • Wei Wang,
  • Qiang Guo,
  • Yanru Zhang

摘要

This study develops a thermo-fluid coupled simulation model to investigate the effects of ultrasonic vibration and substrate preheating on the molten pool behavior and cladding quality in the fabrication of CBN/CuSnTi composite grinding wheels via laser cladding. The model incorporates time-dependent thermophysical properties of a 45# steel substrate and CuSn18Ti9 binder, considering ultrasonic action, substrate temperature, and the Marangoni effect. Four typical process conditions were compared. At room temperature without ultrasound, the molten pool exhibited unidirectional heat flow, weak recirculation, and coarse grains. Introducing ultrasound reduced initial conductive heat flux by 2.19%, shifted the recirculation vortex center downward by 7.8%, and slightly improved grain refinement via enhanced surface tension gradients, but did not break the dominant heat flow pattern. Substrate preheating to 573.15 K alone increased Marangoni convection strength and expanded surface flow, improving pool morphology and grain uniformity while weakening directional solidification. When ultrasound was further applied under preheating, the vortex center dropped 11.96%, peak velocity increased by 1.6 times, and the heat flow became more isotropic, lowering cooling and solidification rates and significantly improving structural compactness. Molten pool height, depth, and width increased by 8.13%, 10.7%, and 0.9%, respectively. These findings clarify the synergistic mechanism of thermal and acoustic effects and offer guidance for parameter optimization in high-performance grinding wheel fabrication.