Study on creep-feed deep grinding of K444 nickel-based superalloy with corundum grinding wheel

To evaluate the grindability of nickel-based superalloy K444, brown alumina and white alumina abrasive wheels were used in this work. The grinding force, specific grinding energy, tool wear, the ground surface morphology and roughness were compared and analyzed. The results showed that brown alumina abrasive wheel had smaller grinding force, lower ground surface roughness compared with white alumina abrasive wheel. The ground surface roughness R_aafter grinding with brown alumina abrasive wheel was 0.20~0.45 μm, it was easier for brown alumina abrasive wheel to obtain a smooth ground surface. The sensitivity analysis of superalloy surface roughness showed that these two kinds of alumina abrasive wheels were the most sensitive to the depth of cut a_p, followed by the workpiece speed v_w, and the least sensitive to the wheel speed v_s. The wear of brown alumina abrasive wheel was lower than white alumina abrasive wheel. When the material removal rate R_MRR was between 0.3 mm³/(mm·s) and 1.0 mm³/(mm·s), the wear ratio of the two grinding wheels was between 1.36 and 1.40.