Influence of High-Pressure Grinding Parameters on Surface Topography and Microstructure

In recent years, high-pressure grinding systems have been developed to remove surface defects created during the continuous casting process, and the subsequent solidification and cooling phases. The high-pressure grinding process uses a controlled and constant force transmission from the grinding wheel, along with a pendulum mode workpiece transport, to achieve consistent and high material removal rates. Contrary to other applications of surface manufacturing, this process has not been investigated sufficiently in fundamental research. The aim of this article is therefore to explore the influence of high-pressure grinding on the surface topography and microstructure of steel-cast semifinished products, and to understand the effects of this machining process on surface quality, material removal, and microstructural changes. For this study, experimental tests are conducted using an industrial high-pressure grinding machine. Various grinding parameters, such as grinding wheel speed, grinding wheel angle, workpiece speed (feed), contact force, and cutting depth, are recorded and analyzed. The results show clear differences in cutting depth and surface topography between the different grinding steps, as well as microstructural changes of the near-surface layers which are observed through light microscopy, scanning electron microscopy, and electron backscatter diffraction.