Point grinding of hardened steel (62 HRC) and a silica based ceramic for aerospace applications

Medina Aguirre, Fernanda Del Rosario (2022). Point grinding of hardened steel (62 HRC) and a silica based ceramic for aerospace applications. University of Birmingham. Ph.D.

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Abstract

The thesis focuses on assessing the abrasive machinability of hardened steel (62 HRC) and silica based ceramic materials using small diameter electroplated wheels/ grinding points (≤ Ø 6 mm) as an alternative manufacturing approach for finishing/producing complex geometry components for aerospace applications. The experimental work carried out was divided into two main phases. Phase 1 evaluated the effect of grit size, cutting parameters, and tool lead angle when grinding with and without ultrasonic vibration on workpiece surface roughness, tool wear and cutting forces when machining hardened steel. Overall, results from Phase 1 trials demonstrated the capability of point grinding to achieve surface finish (⁓ 0.3 μm Ra) comparable to those produced by grinding using large diameter wheels (≥ Ø 150 mm). When point grinding of the silica based ceramic in Phase 2, improved understanding was developed with regard to the influence of tool topography, depth of cut and feed rate on edge chipping and workpiece surface roughness. Subsequently, a benchmarking assessment of the performance of milling cutters and point grinding tools in terms of tool wear, cutting forces, surface roughness and edge quality was conducted to identify the preferred cutting conditions and tool type.

Type of Work:

Thesis (Doctorates > Ph.D.)

Award Type:

Doctorates > Ph.D.

Supervisor(s):