Experimental investigation of cutting forces in dry grinding of Ti-6Al-4V alloy using CNT nano grinding tool

Grinding difficult-to-machine metals like titanium alloys requires a precise surface finish at nanoscale levels. This research examines the surface properties of the Ti-6Al-4 V alloy when ground in dry conditions with Cubic Boron Nitride (CBN) grinding wheels incorporated with varying percentages (2-7%) of carbon nanotubes (CNT). The newly developed CNT-CBN grinding wheels were studied by looking at their damping capacity, circularity and forces generated. Comparison of predicted and experimental surface finish values and Material Removal Rates (MRR) while varying % CNT added to the wheel and identification of optimum grinding parameters through multi-objective optimisation methods was done. This aim is to identify the percentage of CNT inclusion, which improves the grinding wheel's material removal rates and reduces the surface roughness and forces generated in the workpieces simultaneously. The wheels' damping factor was found using free vibrational tests. The circularity was measured using CMM before and after experimentation. Twenty-seven experiments were done following a Full-Factorial design, along with material characterisation. Regression analysis was done, and Fuzzy logic (FL) and Adaptive Neuro-Fuzzy Inference System (ANFIS) were used for modelling. To facilitate multi-criteria decision-making techniques, automate the grinding process, and work with expert systems and allied automation, the Grey Relational Analysis (GRA). These have proved that even low amounts of CNT can improve performance multiple times.