High speed and precision grinding of plasma sprayed oxide ceramic coatings

In this paper, the effects of high speed grinding on six thermally sprayed ceramic coatings were investigated. Grinding was undertaken using four wheel speeds and two work speeds. The responses studied were the following; grinding forces, specific grinding energy, force ratio, surface roughness and surface residual stress. In addition, grinding in traverse mode was also considered in this investigation. An increase in wheel speed resulted in an appreciable reduction in grinding forces. The micro-brittle fracture was the predominant mode of material removal along with micro-cutting in some cases. Further, the surface roughness of traverse ground samples was superior to those obtained using plunge grinding. Finally, it was found that surface residual stresses of samples produced during high-speed grinding are lower than those of samples using precision grinding.