The working surface condition of abrasive tool is one of the important issues in grinding process. This article discusses the effects of the ultrasonic vibration on the working surface condition involving chips adhesion and abrasive grains wear during ultrasonic-assisted grinding (UAG) of Inconel 718 with an electroplated cBN grinding quill as the abrasive tool. In this study, scanning electron microscopic (SEM) observations were performed on the quill working surface before and after grinding at different vibration amplitudes, and the SEM images were filtered, extracted, and binarized by using image-pro plus to evaluate the quill working surface condition. The obtained results demonstrated that (1) the wear of grinding quill is dominantly attributed to chips adhesion, grains releasing, and grains fracture; (2) both the percentage of chips adhesion area and the size of chips adhered tend to decrease as the vibration amplitude increases; in contrast, the effect of ultrasonic vibration on the number of chips adhesion is not noticeable; (3) the percentage of the number of grains released/fractured decreases as the vibration amplitude rises, e.g., the percentage in UAG at vibration amplitude of Ap–p = 9.4 μm was decreased by 40% compared to that in conventional grinding (CG); and (4) higher distribution density of effective cutting edges can be achieved under larger vibration amplitude, and the mean area of effective cutting edges in UAG is smaller than that in CG, demonstrating that the ultrasonication enhances the grinding quill sharpness.
Issue Section:
Research Papers
References
1.
Sharman
, A.
, Dewes
, R. C.
, and Aspinwall
, D. K.
, 2001
, “Tool When High Speed Ball Nose End Milling Inconel 718
,” J. Mater. Process. Technol.
, 118
(1–3
), pp. 29
–35
.2.
Sharman
, A. R. C.
, Hughes
, J. I.
, and Ridgway
, K.
, 2015
, “The Effect of Tool Nose Radius on Surface Integrity and Residual Stresses When Turning Inconel 718
,” J. Mater. Process. Technol.
, 216
, pp. 123
–132
.3.
Radhakrishna
, C. H.
, and Prasad Rao
, K.
, 1997
, “The Formation and Control of Laves Phase in Superalloy 718 Welds
,” J. Mater. Sci.
, 32
(8
), pp. 1977
–1984
.4.
Schrock
, D. J.
, Kang
, D.
, Bieler
, T. R.
, and Kwon
, P.
, 2014
, “Phase Dependent Tool Wear in Turning Ti-6Al-4V Using Polycrystalline Diamond and Carbide Inserts
,” ASME J. Manuf. Sci. Eng.
, 136
(4
), p. 041018
.5.
Herbert
, C.
, Axinte
, D. A.
, Hardy
, M.
, and Withers
, P.
, 2014
, “Influence of Surface Anomalies Following Hole Making Operations on the Fatigue Performance for a Nickel-Based Superalloy
,” ASME J. Manuf. Sci. Eng.
, 136
(5
), p. 051016
.6.
Khidhir
, B. A.
, and Mohamed
, B.
, 2010
, “Machining of Nickel Based Alloys Using Different Cemented Carbide Tools
,” J. Eng. Sci. Technol.
, 5
(3
), pp. 264
–271
.7.
Ulutan
, D.
, and Ozel
, T.
, 2011
, “Machining Induced Surface Integrity in Titanium and Nickel Alloys: A Review
,” Int. J. Mach. Tools Manuf.
, 51
(3
), pp. 250
–280
.8.
Ozcelik
, B.
, Oktem
, H.
, and Kurtaran
, H.
, 2005
, “Optimum Surface Roughness in End Milling Inconel 718 by Coupling Neural Network Model and Genetic Algorithm
,” Int. J. Adv. Manuf. Technol.
, 27
(3
), pp. 234
–241
.9.
Sonawane
, H. A.
, and Joshi
, S. S.
, 2015
, “Analytical Modeling of Chip Geometry in High-Speed Ball-End Milling on Inclined Inconel-718 Workpieces
,” ASME J. Manuf. Sci. Eng.
, 137
(1
), p. 011005
.10.
Kitagawa
, T.
, Kubo
, A.
, and Maekawa
, K.
, 1997
, “Temperature and Wear of Cutting Tools in High-Speed Machining of Inconel 718 and Ti-6Al-6V-2Sn
,” Wear
, 202
(2
), pp. 142
–148
.11.
Tayon
, W. A.
, Shenoy
, R. N.
, Redding
, M. R.
, Keith Bird
, R.
, and Hafley
, R. A.
, 2014
, “Correlation Between Microstructure and Mechanical Properties in an Inconel 718 Deposit Produced Via Electron Beam Freeform Fabrication
,” ASME J. Manuf. Sci. Eng.
, 136
(6
), p. 061005
.12.
Devillez
, A.
, Schneider
, F.
, Dominiak
, S.
, Dudzinski
, D.
, and Larrouquere
, D.
, 2007
, “Cutting Forces and Wear in Dry Machining of Inconel 718 With Coated Carbide Tools
,” Wear
, 262
(7–8
), pp. 913
–942
.13.
Xu
, W.
, Zhang
, L. C.
, and Wu
, Y.
, 2014
, “Elliptic Vibration-Assisted Cutting of Fibre-Reinforced Polymer Composites: Understanding the Material Removal Mechanisms
,” Compos. Sci. Technol.
, 92
, pp. 103
–111
.14.
Welling
, D.
, 2014
, “Results of Surface Integrity and Fatigue Study of Wire-EDM Compared to Broaching and Grinding for Demanding Jet Engine Components Made of Inconel 718
,” Proc. CIRP
, 13
, pp. 339
–344
.15.
Devillez
, A.
, Le Coz
, G.
, Dominiak
, S.
, and Dudzinski
, D.
, 2011
, “Dry Machining of Inconel 718, Workpiece Surface Integrity
,” J. Mater. Process. Technol.
, 211
(10
), pp. 1590
–1598
.16.
Zhena
, J.
, Li
, F.
, Zhu
, S.
, Ma
, J.
, Qiao
, Z.
, Liu
, W.
, and Yang
, J.
, 2014
, “Friction and Wear Behavior of Nickel-Alloy-Based High Temperature Self-Lubricating Composites Against Si3N4 and Inconel 718
,” Tribol. Int.
, 75
, pp. 1
–9
.17.
Ranganath
, S.
, Guo
, C.
, and Holt
, S.
, “Experimental Investigations Into the Carbide Cracking Phenomenon on Inconel 718 Superalloy Material
,” ASME
Paper No. MSEC2009-84085.18.
Nadolny
, K.
, Sienicki
, W.
, and Wojtewicz
, M.
, 2014
, “The Effect Upon the Grinding Wheel Active Surface Condition When Impregnation With Non-Metallic Elements During Internal Cylindrical Grinding of Titanium
,” Arch. Civil Mech. Eng.
, 15
(1
), pp. 529
–533
.19.
Zemzemi
, F.
, Rech
, J.
, Ben Salem
, W.
, Dogui
, A.
, and Kapsa
, Ph.
, 2014
, “Identification of Friction and Heat Partition Model at the Tool-Chip-Workpiece Interfaces in Dry Cutting of an Inconel 718 Alloy With CBN and Coated Carbide Tools
,” Adv. Manuf. Sci. Technol.
, 38
(1
), pp. 5
–22
.20.
Malkin
, S.
, and Cook
, N. H.
, 1971
, “The Wear of Grinding Wheels, Part 2-Fracture Wear
,” ASME J. Manuf. Sci. Eng.
, 93
(4
), pp. 1129
–1133
.21.
Linke
, B. S.
, 2015
, “Review on Grinding Tool Wear With Regard to Sustainability
,” ASME J. Manuf. Sci. Eng.
, 137
(6
), p. 060801
.22.
Adibi
, H.
, Rezaei
, S. M.
, and Sarhan
, A. A. D.
, 2013
, “Grinding Wheel Loading Evaluation Using Digital Image Processing
,” ASME J. Manuf. Sci. Eng.
, 136
(1
), p. 011012
.23.
Ismail
, M. F.
, Yanagi
, K.
, and Isobe
, H.
, 2012
, “Geometrical Transcription of Diamond Electroplated Tool in Ultrasonic Vibration Assisted Grinding of Steel
,” Int. J. Mach. Tools Manuf.
, 62
, pp. 24
–31
.24.
Nik
, M. G.
, Movahhedy
, M. R.
, and Akbari
, J.
, 2012
, “Ultrasonic-Assisted Grinding of Ti6Al4V Alloy
,” Proc. CIRP
, 1
, pp. 353
–358
.25.
Park
, K.-H.
, Hong
, Y.-H.
, Kim
, K.-T.
, Lee
, S.-W.
, Choi
, H.-Z.
, and Choi
, Y.-J.
, 2014
, “Understanding of Ultrasonic Assisted Machining With Diamond Grinding Tool
,” Mod. Mech. Eng.
, 4
(1
), pp. 1
–7
.26.
Cao
, J.
, Wu
, Y.
, Lu
, D.
, Fujimoto
, M.
, and Nomura
, M.
, 2014
, “Material Removal Behavior in Ultrasonic-Assisted Scratching of SiC Ceramics With a Single Diamond Tool
,” Int. J. Mach. Tools Manuf.
, 79
, pp. 49
–61
.27.
Subramanian
, K.
, Ramanath
, S.
, and Tricard
, M.
, 1997
, “Mechanism of Material Removal in the Precision Grinding of Ceramic
,” ASME J. Manuf. Sci. Eng.
, 119
(4A
), pp. 1
–19
.28.
Wang
, Y.
, Lin
, B.
, Wang
, S.
, and Cao
, X.
, 2014
, “Study on the System Matching of Ultrasonic Vibration Assisted Grinding for Hard and Brittle Materials Processing
,” Int. J. Mach. Tools Manuf.
, 77
, pp. 66
–73
.29.
Liang
, Z.
, Wu
, Y.
, Wang
, X.
, and Zhao
, W.
, 2010
, “A New Two-Dimensional Ultrasonic Assisted Grinding (2D-UAG) Method and Its Fundamental Performance in Monocrystal Silicon Machining
,” Int. J. Mach. Tools Manuf.
, 50
(8
), pp. 728
–736
.30.
Mult
, H. C.
, Spur
, I. G.
, and Holl
, S.-E.
, 1996
, “Ultrasonic Assisted Grinding of Ceramics
,” J. Mater. Process. Technol.
, 62
(4
), pp. 287
–293
.31.
Pei
, Z. J.
, Ferreira
, P. M.
, Kapoor
, S. G.
, and Haselkorn
, M.
, 1995
, “Rotary Ultrasonic Machining for Face Milling of Ceramics
,” Int. J. Mach. Tools Manuf.
, 35
(7
), pp. 1033
–1046
.32.
Liu
, D. F.
, Cong
, W. L.
, Pei
, Z. J.
, and Tang
, Y. J.
, 2012
, “A Cutting Force Model for Rotary Ultrasonic Machining of Brittle Materials
,” Int. J. Mach. Tools Manuf.
, 52
(1
), pp. 77
–84
.33.
Zahedi
, A.
, Tawakoli
, T.
, and Akbari
, J.
, 2015
, “Energy Aspects and Workpiece Surface Characteristics in Ultrasonic Assisted Cylindrical Grinding of Alumina-Zirconia Ceramics
,” Arch. Civil Mech. Eng.
, 90
, pp. 16
–28
.34.
Bhaduri
, D.
, Soo
, S. L.
, Aspinwall
, D. K.
, Novovic
, D.
, Harden
, P.
, Bohr
, S.
, and Martin
, D.
, 2012
, “A Study on Ultrasonic Assisted Creep Feed Grinding of Nickel Based Superalloys
,” Proc. CIRP
, 1
, pp. 359
–364
.35.
Bhaduri
, D.
, Soo
, S. L.
, Novovic
, D.
, Aspinwall
, D. K.
, Harden
, P.
, Waterhouse
, C.
, Bohr
, S.
, Mathieson
, A. C.
, and Lucas
, M.
, 2013
, “Ultrasonic Assisted Creep Feed Grinding of Inconel 718
,” Proc. CIRP
, 6
, pp. 616
–621
.36.
Tso
, P.-L.
, 1995
, “Study on the Grinding of Inconel 718
,” Int. J. Mater. Process. Technol.
, 55
(3–4
), pp. 421
–426
.37.
Marinescu
, I. D.
, Hitchiner
, M. P.
, Uhlmann
, E.
, Brian Rowe
, W.
, and Inasak
, I.
, 2006
, Handbook of Machining With Grinding Wheels
, CRC, Technology and Engineering
, New York, p. 632
.38.
Kapłonek
, W.
, and Nadolny
, K.
, 2013
, “Assessment of the Grinding Wheel Active Surface Condition Using SEM and Image Analysis Techniques
,” J. Braz. Soc. Mech. Sci. Eng.
, 35
(3
), pp. 207
–215
.39.
Kapłonek
, W.
, Łukianowicz
, C.
, and Nadolny
, K.
, 2012
, “Methodology of the Assessment of the Abrasive Tool's Active Surface Using Laser Scatterometry
,” Trans. Can. Soc. Mech. Eng.
, 36
(1
), pp. 49
–66
.40.
Sharp
, K. W.
, Miller
, M. H.
, and Scattergoodc
, R. O.
, 2000
, “Analysis of the Grain Depth-of-Cut in Plunge Grinding
,” Precis. Eng.
, 24
(3
), pp. 220
–230
.41.
Agarwal
, S.
, and Venkateswara Rao
, P.
, 2008
, “Experimental Investigation of Surface/Subsurface Damage Formation and Material Removal Mechanisms in SiC Grinding
,” Mach. Tools Manuf.
, 48
(6
), pp. 698
–710
.42.
Sharp
, K. W.
, Miller
, M. H.
, and Scattergoodc
, R. O.
, 2008
, “Micro Fracture Behavior of Cutting Edges in Grinding Using Single Crystal cBN Grains
,” Diamond Relat. Mater.
, 17
(7–10
), pp. 1759
–1763
.43.
Lv
, D.
, Wang
, H.
, Tang
, Y.
, and Huang
, Y.
, 2012
, “Surface Observations and Material Removal Machining of Brittle Material
,” Int. J. Eng. Manuf.
, 226
(9
), pp. 1
–10
.44.
Agarwal
, S.
, and Venkateswara Rao
, P.
, 2013
, “Predictive Modeling of Force and Power Based on a New Analytical Undeformed Chip Thickness Model in Ceramic Grinding
,” Int. J. Mach. Tools Manuf.
, 65
, pp. 68
–78
.45.
Wu
, Y.
, Nomura
, M.
, Feng
, Z.
, and Kato
, M.
, 2004
, “Modeling of Grinding Force in Constant-Depth-of-Cut Ultrasonically Assisted Grinding
,” Mater. Sci. Forum
, 471
(2
), pp. 6
–10
.Copyright © 2016 by ASME
You do not currently have access to this content.
