Intermittent grinding of ceramic matrix composites (CMCs) utilizing a developed segmented wheel

Ceramic matrix composites (CMCs) are relatively new and promising materials for many high-technology engineering applications in harsh and severe environments due to their superior properties. Despite being mostly at the development phase, CMCs have some very successful applications in several high technology fields. However, in spite of all advantages, the employment of CMCs has been impeded by their high machining and finishing costs. Many recently developed CMCs are very difficult to machine with conventional machining technology, and improvement of the existing machining process is required and crucial. The main objectives for overcoming these technological constraints are reducing high grinding forces and tool wear, improving surface integrity and increasing material removal rate. To overcome the existing technological constraints in the grinding of CMCs, a specially designed segmented wheel has been developed. Reducing the static cutting edges via segmenting the wheel, which automatically leads to reduction of momentarily engaging cutting edges, results in a reduction of rubbing and plowing regimes. Consequently, the specific grinding energy decreases. Experimental results illustrate the high performance of the presented method. A significant reduction in normal and tangential grinding forces and an increase in G-ratio have been achieved.