Fabrication Process and Surface Morphology Prediction of Radial Straight Groove-Structured CBN Grinding Wheel by Laser Cladding.

Structured CBN (cubic boron nitride) grinding wheels usually have a specially designed texture on their surface to reduce the grinding heat and grinding force. However, most structured grinding wheels are fabricated by electroplating, brazing, sintering, and mechanical or laser removal on the surface of conventional grinding wheels, which may have problems such as complicated processes, low processing efficiency, and unstable effects. In this paper, additive manufacturing was used to fabricate a radial straight groove-structured grinding wheel. Meanwhile, a corresponding mathematical model of the grinding wheel was also established considering the shape and position of the abrasive grains. Subsequently, the ground surface morphologies of the fabricated wheel and simulated wheel under different machining parameter conditions were compared to further prove the rationality of the simulated grinding wheel. The results showed that the ground surfaces of the fabricated wheel and simulated wheel had similar morphological characteristics. The trend in the surface roughness under the different machining parameter conditions was also analyzed and showed the same variation for fabricated and simulated wheels; the error rate was confined within 8%. This paper elucidates the grinding mechanism and surface morphology formation process of a radial straight groove-structured grinding wheel fabricated by additive manufacturing.