Influence of Technological Factors on the Cutting Ability of Wheels and Energy Consumption during Grinding of a Microporous Coating

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发表日期：

2024年12月1日

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V. A. Kaporin,
N. S. Alekseev,
S. V. Ivanov

摘要

Abstract—Wear-resistant nickel-based microporous coatings represent a class of difficult-to-machine materials, which pose significant challenges during abrasive processing. The primary machining difficulties during grinding stem from rapid abrasive wheel degradation due to both tool dulling and active adhesion of coating particles to the working surface. A parameter optimization framework is developed to improve rough grinding performance of microporous coatings, simultaneously extending wheel life and reducing specific energy consumption. The experimental results used to estimate the cutting capacity of aluminum oxide grinding wheels during cylindrical plunge grinding of microporous coatings are presented. The dependences of the cutting capacity coefficient (K_c) and the specific grinding power (N_sp) on process parameters, such as the cutting speed, the workpiece speed, and the radial feed rate, as well as on wheel characteristics, such as the abrasive grain size and the hardness, are investigated. The methodology and experimental results of plunge grinding for microporous coatings are described. A designed active experiment is used. A 2^5–2 fractional factorial design is used. The levels of technological factors, level values, and their ranges of variation are given. The levels of the factors are justified. The experimental conditions are detailed, including the chemical composition of the plasma-sprayed coatings under study and the sample sizes. Statistical analysis is performed to develop mathematical models to characterize the influence of cutting conditions and wheel characteristics on the response surfaces (cutting capacity coefficient K_c, specific grinding power N_sp). The developed mathematical models are analyzed, and the results obtained are interpreted. The models enable optimization of the cutting conditions and the characteristics of abrasive tool to maximize the grinding wheel durability.