Quadratic Response Surface Modeling of Surface Roughness in CBN Grinding of HARDOX 500
Abstract
This study investigates the influence of grinding parameters on surface roughness (Ra) in grinding HARDOX 500 steel with a CBN wheel, using a quadratic Response Surface Methodology (RSM). A full quadratic model, including linear, interaction, and squared terms, was initially developed and subsequently simplified through stepwise selection based on the Akaike Information Criterion (AIC). The full model achieved R² = 0.987 and adjusted R² = 0.964, while the simplified model achieved R² = 0.985 and adjusted R² = 0.974, indicating strong predictive capability with reduced complexity. Analysis of variance (ANOVA) and partial effect size (η²) revealed that the squared term of depth of cut (t²) exerted the dominant and statistically significant influence on Ra (p < 0.001). In contrast, spindle speed, feed rate, and their higher-order terms played only minor or negligible roles. Diagnostic plots confirmed model adequacy, with residuals evenly distributed and predicted values closely matching experimental data. The findings highlight that precise control of depth of cut is the key factor in achieving the desired surface quality when grinding HARDOX 500 steel, providing practical guidance for optimizing process parameters in industrial applications.
Tài liệu tham khảo
[1] Z. Wang et al., "No-impact trajectory design and fabrication of surface structured CBN grinding wheel by laser cladding remelting method," Optics & Laser Technology, vol. 181, p. 111956, 2025.
[2] P. Breuer, T. Künkel, J. Werner, U. Müller, T. Bergs, and T. E. Weirich, "Investigation of the structural stability of polycrystalline cBN under near-industrial grinding process conditions," International Journal of Refractory Metals and Hard Materials, vol. 122, p. 106720, 2024.
[3] H. Jamshidi, A. Bagherzadeh, E. Budak, and H. Ghadbeigi, "A predictive wear model in grinding using single-layer electroplated cBN tools," Journal of Manufacturing Processes, vol. 127, pp. 251-258, 2024.
[4] L. Benkai et al., "Design and grindability assessment with cup shaped electroplated CBN wheel grinding turbine disc slots of powder metallurgy superalloy FGH96," Chinese Journal of Aeronautics, vol. 37, no. 9, pp. 521-534, 2024.
[5] M. Bredthauer, P. Snellings, P. Mattfeld, and T. Bergs, "Wear-related topography changes for electroplated cBN grinding wheels and their effect on thermo-mechanical load," Wear, vol. 512, p. 204543, 2023.
[6] M. Deja, "The use of Preston equation to determine material removal during lap-grinding with electroplated CBN tools," Wear, vol. 528, p. 204968, 2023.
[7] B. Zhao, W. Ding, G. Xiao, K. Cai, Z. Li, and C. Pu, "Micro-fracture behavior of a single-aggregated CBN grain and its relation to material removal in high-speed grinding of Ti–6Al–4V alloys," Journal of Manufacturing Processes, vol. 79, pp. 19-27, 2022.
[8] B. Guo, Q. Meng, S. Li, G. Wu, Y. Xiang, and Q. Zhao, "Pulse laser precision truing of the V-shaped coarse-grained electroplating CBN grinding wheel," Materials & Design, vol. 217, p. 110650, 2022.
[9] B. K. Sato et al., "Novel comparison concept between CBN and Al2O3 grinding process for eco-friendly production," Journal of Cleaner Production, vol. 330, p. 129673, 2022.
[10] N. Qian, Y. Fu, F. Jiang, W. Ding, J. Zhang, and J. Xu, "CBN grain wear during eco-benign grinding of nickel-based superalloy with oscillating heat pipe abrasive wheel," Ceramics International, vol. 48, no. 7, pp. 9692-9701, 2022.
[11] C. Zhang, S. Qu, W. Xi, Y. Liang, J. Zhao, and T. Yu, "Preparation of a novel vitrified bond CBN grinding wheel and study on the grinding performance," Ceramics International, vol. 48, no. 11, pp. 15565-15575, 2022.
[12] P.-z. Liu, Y. Yao, W.-j. Zou, J. Peng, X.-d. Song, and F.-r. Xiao, "Design of a CBN composite abrasive to improve the performance of HSG rail maintenance grinding wheel," Construction and Building Materials, vol. 319, p. 126073, 2022.
[13] G. Xiao, B. Zhao, W. Ding, and H. Huan, "On the grinding performance of metal-bonded aggregated cBN grinding wheels based on open-pore structures," Ceramics International, vol. 47, no. 14, pp. 19709-19715, 2021.
[14] W. Ding, B. Zhao, Q. Zhang, and Y. Fu, "Fabrication and wear characteristics of open-porous CBN abrasive wheels in grinding of Ti–6Al–4V alloys," Wear, vol. 477, p. 203786, 2021.