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422 Abrasive Types
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Abrasive grains used for grinding wheels are very hard, highly refractory materials and are randomly oriented Although brittle, these materials can withstand very high temperatures They have the ability to fracture into smaller pieces when the cutting force increases This phenomenon gives these abrasives a self-sharpening effect During grinding, whenever dulling begins, abrasive fractures and new cutting points are created Four types of abrasives commonly used are as follows: (i) Aluminium oxide or alumina (Al2O3) (ii) Silicon carbide (SiC) (iii) Cubic Boron Nitride (CBN) (iv) Diamond (v) Tungsten carbide (WC) Aluminium oxide and silicon carbides are known as conventional abrasives, whereas CBN and diamond are known as superabrasives The aluminium oxide wheel is generally used for grinding metals such as carbon steel, alloy steel, high-speed steel, annealed malleable iron, wrought iron and bronzes and other similar metals On the other hand, the silicon carbide wheel is harder but is more brittle than the alumina wheel and is commonly used to grind low tensile strength materials such as grey iron, chilled iron, brass, soft bronze and aluminium, as well as stone/marble, rubber, leather and other non-ferrous metals [10][11] Diamond wheels are suitable for machining non-ferrous metal, whereas CBN is normally good for grinding ferrous metal However, the latter is also used for grinding titanium alloys, and its performance is better than SiC and Al2O3 wheels [12] Aluminium oxide wheels are often replaced by CBN wheels for hardened steel (>45H Rc), superalloys (nickel, cobalt or iron based with a hardness greater than 35 H Rc), high-speed steels and cast iron CBN has four times the abrasion resistance of aluminium oxide The high thermal conductivity of CBN prevents heat buildup and associated problems such as wheel glazing and workpiece metallurgical damage [11] A comparison of some properties of these abrasives with those of hardened steel and glass are shown in Table 41 Table 41 shows that diamond has promising properties compared to the other three abrasives One of the unique properties of diamond that stands out is its extreme hardness Because of this, diamond is a material with the greatest resistance and thermal conductivity among all known substances It is also chemically inert Chemical inertness normally prevents the diamond from bonding to or reacting with other substances [14] For these reasons, it is the most desirable abrasive for many applications, but there are limitations to its usefulness other than its cost The surface chemistry of
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Advances in Precision Grinding
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Table 41
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Properties of some hard and brittle materials [7] [11] [13]
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Material type Hardened steel Glass Aluminium oxide
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Melting point ( C) 1371 1532 350 750 2040 2050 2830 2500 3200 3700
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Thermal conductivity (W/m K) 15 52 06 17 29
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Hardness (kg/mm2) 700 1300 300 810 2000 3000
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Density (kg/m3) 6920 9130 2270 6260 4000 4500
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Silicon carbide
63 155
2100 3000
Cubic boron nitride Diamond
1300 2000
4000 5000 7000 8000
3480 3500
diamond limits is useful in certain conditions Diamond is made of carbon, and at high enough temperatures will burn, or will react with carbide-forming metals If either event occurs to any significant extent, the diamond structure is lost The service conditions that are required to avoid such losses are low temperatures and avoidance of carbide-forming metals except when close to the room temperature such as in lapping and polishing operations The high thermal conductivity of diamond helps to relieve the problem by conducting the heat away [15] Diamonds are excellent for machining non-ferrous metal (such as copper, zinc, aluminium and their alloys), plastics, ceramics, glass, fibreglass bodies, graphite and other highly abrasive materials Although diamonds are very hard, they get worn out when machining steel, titanium alloys and stainless steel because they consist of pure carbon The carbon in diamond dissolves in -Fe at a high rate at a temperature greater than 900 C [16] Diamonds are also not particularly effective for machining superalloys that contain cobalt or nickel probably because of the same reason as stated earlier [16] A recent study on grinding wear mechanisms has shown that the CBN wheel is superior to Al2O3 and SiC wheels due to the greater chemical stability of CBN at higher temperatures when grinding titanium alloy (Ti6Al4V) and nickel-based alloy (K417) [12] The use of tungsten carbide (WC) has been explained in the section on mounted wheels
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