Electrochemical superabrasive machining of a nickel-based aeroengine alloy using mounted grinding points

Brief design and manufacture considerations are detailed for a hybrid electrochemical grinding unit adapted from a vertical machining centre using a 40,000 rpm spindle and 500 A DC generator. Subsequently, experimental work is presented on the influence of tool bond systems, superabrasive grit type and electrical parameters when Simultaneous ECM/grinding Udimet 720 using 10-15 mm diameter plain points. Single layer electroplated CBN tools produced G-ratios and maximum normal cutting forces of similar to 451 and similar to 45 N, respectively, compared to similar to 128 and 557 N for equivalent diamond wheels. Data on workpiece toughness and overcut are also presented as are initial results for a fir tree shaped tool. (C) 2009 CIRP.