Grinding performance of a new micro-crystalline corundum wheel when form-grinding automobile gears

To study the performance of the new, self-developed micro-crystalline corundum wheel, comparative experimental research into the form grinding of a 20CrMnTi steel tooth using a new micro-crystalline corundum wheel, a Reishauer micro-crystalline corundum wheel and a white corundum (WA) grinding wheel was conducted. The grinding performances were compared in terms of grinding force, grinding heat, surface roughness and grinding-induced surface defects. The wear patterns of micro-crystalline corundum grains were also analysed. A comprehensive evaluation system for grinding wheel performance was established based on the grey relational analysis method. The results show that the grinding forces and grinding temperature produced by the new micro-crystalline corundum wheel are always lower than those generated by the WA wheel and similar to those of the Reishauer micro-crystalline corundum wheel. Although the coating, adhesion of adhesive chips, deep grooves and micro-cracks are the four dominant grinding-induced defects, the micro-crystalline corundum wheel produces fewer surface defects and a better surface quality. The maximum value of grey relativity is obtained by using the new micro-crystalline corundum wheel with the following grinding parameters: vs = 50 m/s, ap = 0.1 mm and vw = 3.5 m/min. The average grey relativity obtained with the new micro-crystalline corundum wheel is much higher than that with the WA wheel and slightly higher than that with the Reishauer micro-crystalline corundum wheel. These results indicate that the new grinding wheel offers the best comprehensive grinding performance.