Performance enhancement of single-layer miniature cBN wheels using CFUBMS-deposited TiN coating

This work investigated the effectiveness of TiN coating in enhancing the performance of two different types of single-layer cBN grinding wheels. One was galvanically bonded type where galvanic metal layer covered less than 50% of the grit height. In this paper, it is termed as underplated wheel. The other one was brazed cBN wheel which was developed in-house. In this case, the grits were bonded by a braze alloy layer. TiN coating, well known for its anti-wear and anti-friction characteristics, finds use in cutting tools and tribological applications. In this case study, such TiN was successfully deposited on the above-mentioned two types of grinding wheels with a dual cathode closed-field unbalanced magnetron sputtering (CFUBMS) system. Performance of those TiN-coated wheels was compared with that of uncoated counterparts in terms of grinding force and percentage of grit failure. Grinding tests were carried out in plunge mode and under dry condition. Experimental results clearly revealed the fact that the role of TiN coating was not that significant in reducing the friction at the wheel-workpiece contact zone. However, it was able to substantially reduce grit pullout of the underplated cBN wheel. On the other hand, uncoated brazed cBN wheel did not suffer from grit pullout, but severe premature breakage of cBN grits at the bond level was observed. This was remarkably arrested when TiN coating was applied on the active surface of the wheel.