Fabrication of Large Alumina Grit-Based Monolayer Grinding Wheel through Electroplating Followed by Detonation Gun Spray Technique for Increased Material Removal

Abstract

Alumina grits of three different sizes (16, 24, and 36 mesh) are attached to the steel wheel hubs by two techniques: (1) electroless Ni bond coat followed by D-gun-sprayed Ni-5Al top coat and (2) electroplated Ni bond coat followed by D-gun-sprayed Ni-5Al top coat to fabricate alumina grit-based monolayer grinding wheels. The prepared wheels are compared on the basis of their coating characteristics. The x-ray diffractometer, field emission scanning electron microscope, and Vickers microhardness test instruments are employed for studying the phases, microstructure, and hardness of the coatings, respectively. The average surface roughness of the as-coated wheels and machined steels is estimated by the contact-type stylus profilometer. The morphology of ground surfaces and removed chips is studied by using an optical microscope. Further, the performance of fabricated grinding wheels is analyzed and compared on the basis of grit failure mode, material removal rate (MRR), and roughness of the ground surfaces. The life of the electroplated Ni-based wheel is found to be more than that of the electroless Ni-based wheel. In addition, the MRR of such a wheel is found to be more than the same of the conventional wheel. Electroplated Ni followed by D-gun-sprayed Ni-5Al-coated wheel is found to be beneficial in protecting the surface from high cutting temperatures and can be used to grind steels with high MRR. © 2023, ASM International.