Study on the removal mechanism in multi-abrasive micro-grinding of nickel-based superalloy

This study introduces a pioneering three-dimensional simulation model for Abaqus multi-grit grinding, developed via Python’s secondary capabilities. The model generates random 48-sided abrasive grains arranged on a cylinder following a characteristic distribution pattern, thus emulating a 200-grit micro-abrasive rod. The model considers varying spindle speeds, grinding depths, and feed rates to investigate the influence of multi-grit on the surface profiles of chips and workpieces for the nickel-based single-crystal Superalloy DD5. The multi-grain simulation reveals that grain 1 produces serrated chips at 60 kr/min in 46% of the global process, increasing to 60% at 80 kr/min. Abrasive generation and grinding initiation occur 10% and 12% earlier, respectively, at 100 kr/min compared to 80 kr/min Additionally, peak grinding forces rise with displacement as spindle speed increases. With a feed rate of 2 m/s, serrated chips constitute 36% of the global process in grain 1, increasing to 50% at 3 m/s. At a peak feed rate of 4 m/s, grinding force decreases as displacement increases. The normal distribution of abrasive particles causes an increase in the number of particles involved in grinding as grinding depth grows. This innovative model contributes valuable insights into the complex dynamics of multi-grit grinding processes and optimization strategies.