Comparative investigation on wear behavior of brown alumina and microcrystalline alumina abrasive wheels during creep feed grinding of different nickel-based superalloys

This study investigates the comparative wear behavior of brown alumina (BA) and microcrystalline alumina (MA) alumina abrasive wheels and its effect on the creep feed ground surface of different nickel-based superalloys, such as wrought alloy GH4169, directional solidified alloy DZ408 and single crystal solidified alloy DD6. The abrasive wheel wear topography was characterized and an analytical model was developed to evaluate the abrasive wheel wear comprehensively. Finally, the effects of tool wear on the grinding performance and ground surface were discussed. Results obtained indicate that, compared with BA abrasive wheel, the MA wheel performed better in terms of the grinding ratio and tool wear behavior. Strong adhesion wear and attritious wear of the abrasive wheels were generated during grinding of GH4169 and DZ408 alloys, while great wheel clogging occurred during grinding of DD6 alloy. Moreover, DZ408 alloy produced the most severe tool wear and largest grinding forces, followed by GH4169 and DD6 alloys. The defects pattern of ground surface with BA wheel was unparallel to the grinding direction due to the grain dislodging and fracture; however, when grinding with MA wheel, groove defects were created along the grinding direction due to high ductility and hardness of grains.