Characterization of the Grinding Process of Airfoil-Shaped Geometries Using Superabrasive Machining

Characterization of the Grinding Process of Airfoil-Shaped Geometries Using Superabrasive Machining | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Characterization of the Grinding Process of Airfoil-Shaped Geometries Using Superabrasive Machining Hector Bravo, Naiara Ortega, Roberto Polvorosa, Ainhoa Castrillo, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6188044/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 07 May, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Electroplated cBN tools are widely used in superabrasive machining (SAM) processes for grinding nickel-based alloys, which play a crucial role in the aerospace industry. These tools are commonly employed for machining airfoils and vanes, but their application in manufacturing of Integrated Blade Rotors (IBRs) airfoils remains limited. This study presents a methodology for evaluating the performance of SAM when machining geometrical surfaces analogous to IBR airfoils. Test parts made from Inconel 718 where machined by cBN electroplated wheel with two different grit sizes, 46 µm and 76 µm, and two different concentrations to analyse the influence of key process parameters, including cutting speed, feed rate, and grinding wheel characteristics, on specific energy, cutting forces, wheel wear, and part surface roughness and metallurgical integrity. The results reveal that at higher levels of aggressiveness, 76 micrometer grits lead to up to 15% lower specific energies, whereas this trend reverses as aggressiveness decreases. Cutting force ratio remains more stable at higher aggressiveness levels, showing no significant variation across different grit sizes or concentrations under the studied conditions. Surface roughness is primarily influenced by grit size, while wear induced by cutting conditions playing a secondary role. No significant defects were found on the produced surfaces. Grinding cBN Electroplated wheel Grain size Nickel based alloys Full Text Supplementary Files AL11P2Complete.xlsx Acondicionamiento.xlsx DesviacionDimensionalZonas.xlsx EspecificEnergy.xlsx ForceRatio.xlsx MachingConditions.xlsx SpecificEnergySuctionSide.xlsx Cite Share Download PDF Status: Published Journal Publication published 07 May, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Accept as is for Publication 26 Apr, 2025 Reviewers agreed at journal 11 Apr, 2025 Reviewers invited by journal 11 Apr, 2025 Editor assigned by journal 10 Apr, 2025 First submitted to journal 09 Apr, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6188044","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":441508807,"identity":"67c62d41-5e1e-46dc-9140-cc164b6656db","order_by":0,"name":"Hector 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Cutting force ratio remains more stable at higher aggressiveness levels, showing no significant variation across different grit sizes or concentrations under the studied conditions. Surface roughness is primarily influenced by grit size, while wear induced by cutting conditions playing a secondary role. 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