Experimental Research On High Efficiency Deep Grinding Of Alumina Ceramics With Brazed Diamond Wheel

Currently, using diamond grinding wheel is the main way of machining of alumina ceramics. However, the high hardness and wear resistance of alumina ceramic material cause lots problems during grinding: the life of wheel wear is poor, the machined surface quality is difficult to control, and etc. Lost previous investigations reveal that these greatly depend on the wheel performance. As having large chip space and strong metallurgical chemical interaction between diamond abrasive grains and brazing alloys, brazed diamond wheel has been considered to a potential tool for efficiently grinding of alumina ceramics.In this work, a brazed diamond was employed to grinding alumina ceramic(99%)with high grinding speed and deep grinding depth. The grinding forces, acoustic emission, SEM morphology, surface roughness Ra and residual stress of ground surface were observed and discussed. All work in this paper can be summarized as follows:(1) Using brazing diamond grinding wheel to high efficiency deep grinding alumina ceramics is feasible. In this work, the maximum grinding speed is 120m/s,the maximum grinding depth is 4mm and the maximum material removal rate reaches to 24mm3/mm·s.(2) The grinding force, the RMS value of acoustic emission, grinding force ratio,grinding specific energy have positive linearly relationship with the maximum chip thickness deformation.(3) The RMS value of acoustic emission has positive linear relationship with the spindle power and grinding force.(4) The surface roughness value(Ra) increases with the expanding of grinding speed. Under different grinding parameters, the Ra values on the vertical feed direction is larger than those on the parallel feed direction.(5) In this work, the way of material removal is mainly in brittle removal.(6) The residual stresses show that the residual stress obtained in this work were allcompressive stress. And the value decreases with the increase of grinding speed and grinding depth, and increases with the increase of feeding.(7) Improving grinding speed and grinding depth and reducing feeding speed are prefer to the high efficiency grinding of alumina ceramicsurrently.