Modeling and optimization of profile creep-feed grinding with cubic boron nitride

Grinding is one of the most critical and costly manufacturing processes accounting for approximately 20% of the total machining expenditures in industrialized countries. Profile creep-feed grinding is essential to a wide range of applications including gas, turbines, cardan shafts and driving elements such as gears. Originally, this process was carried out with aluminum oxide (Al2O3); however, a relatively new alternative being used in Europe and Japan is Cubic Boron Nitride (CBN). CBN is a man-made material that is more than twice as hard as aluminum oxide and has excellent thermal conductivity. As a result, it does not require continuous dressing (to maintain wheel sharpness) and tends to cut at lower temperatures resulting in increased productivity and improved part quality. Canadian companies, however, have been reluctant to adopt this technology partly due to a lack of regional expertise. Furthermore, many Canadian aerospace companies find it difficult to compete simply because of the scarcity of skilled people. To maintain global competitiveness in aerospace manufacturing, Canadian expertise in grinding theory and technology is required.For these reasons, the long-term objective of this research program is to improve the quality and productivity of the grinding process by increasing our fundamental understanding of the grinding process and by developing innovative grinding technology. In particular research on the micro-mechanics of grinding with CBN, management of the high temperatures associated with profile creep-feed grinding, and new more effective coolant delivery systems will be developed. This research will make significant contributions to grinding knowledge and technology, and will develop Canadian expertise and competitiveness in grinding through the training of highly qualified personnel in this key precision machining process.