A Cu-based ceramic porous abrasive ring with phyllotactic pattern in internal cooling grinding of Inconel 718

A Cu-based Al2O3 ceramic cenosphere porous abrasive ring with phyllotactic pattern was fabricated and assembled into the internal cooling wheel, aiming to the improvement of surface integrity in grinding of superalloy. The fracture appearance of sintered materials was analyzed, and the effects of heating temperature or cenospheres content on bending strength and wettability were studied. Then, the abrasive arrangement on porous materials was investigated, and the wheel was assembled for grinding. Findings show that the optimized sintering parameters promote the tight bonding between metal powder and cenospheres, thus the porous and substantial structures were formed for the coolant storage and chip tolerance. Moreover, the brazed abrasive grain clusters are intact, and the flow field simulation confirms the advantages of movement of coolant. Subsequently, the grinding reveals that the porous material improves the overheating in processing. Form the structure of the abrasive arrangement, the phyllotactic pattern has better machining capacity, while the phyllotaxy with larger distribution angle further perfects the performance. Compared with the conventional disordered arrangement, the phyllotaxy has lower grinding temperature, surface roughness and hardening degree, and the grinding track on the workpiece is shallow, also the surface is flat and smooth.