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Impact of Dressing Infeed on SiC Wheel for Grinding Ti-6Al-4V

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Impact of Dressing Infeed on SiC Wheel for Grinding Ti-6Al-4V

Manish Mukhopadhyay1, Pranab Kumar Kundu1, Souvik Chatterjee2 and Santanu

Das2

1
Mechanical Engineering Department, National Institute of Technology Sikkim, Ravangla,
South Sikkim 737139, India

2
Mechanical Engineering Department, Kalyani Government Engineering College, Kalyani-
741235, Nadia, India

Address correspondence to Pranab Kumar Kundu, Department of Mechanical Engineering,

National Institute of Technology Sikkim, Ravangla, South Sikkim 737139, India. Email:
pranabkundu@gmail.com/ pranab@nitsikkim.ac.in
Impact of Dressing Infeed on SiC Wheel for Grinding Ti-6Al-4V

Abstract: Present experimental investigation is directed towards the optimization

of dressing infeed for silicon carbide (SiC) wheel to be employed for grinding
difficult-to-machine super alloy Ti-6Al-4V. Grinding wheels are dressed using
separate, however, identical 0.75 carat single point diamond dressers at 5, 10, 15,
20 and 25 µm infeed values. Differently dressed wheels are consequently, applied
for grinding Ti-6Al-4V under different infeed values of 5, 10 and 15 µm. All the
operations have been performed at a constant velocity of 14 m/min. The
performances of the differently dressed SiC wheels are evaluated based on the
variations of grinding force components, average surface roughness values,
grinding ratio, chip forms and based on the analyses of the micrographs of wheel
topologies and also of the ground surfaces, obtained using scanning electron
microscope (SEM). Following the performance evaluation, the optimized
dressing infeed has been found to be 20 µm for the operation range considered
herein.

Keywords: Grinding; Dressing; infeed; optimization; diamond; SiC; wheel; Ti-

6Al-4V

Introduction
Manufacturing industry relies heavily on the usage of superalloys owing to their greater
reliability and confidence on several applications. Titanium alloys are such super alloys, widely
used in automotive, aerospace, petrochemical and biomedical industries due to their attractive
properties like, high specific strength, low specific gravity, high corrosive resistance, bio-
compatibility, etc. Among the titanium alloys, Ti-6Al-4V is extensively used alloy, the
applications of which can be found in different fields i.e., aircraft turbines, aircraft landing
gears, aerospace fasteners, turbine blades, hip replacement inserts, etc.[1,2]. Owing to its
applications, Ti-6Al-4V is required to be processed into products having high dimensional
accuracy and closed tolerances [3,4].
Grinding, being one of the commonly used surface finishing operations has become popular to
generate desired surfaces of Ti-6Al-4V. Nevertheless, it is itself a relatively complex operation
that requires comparatively greater amount of force and energy for material removal.
Furthermore, the adverse properties of the so called difficult-to-machine (DTM) material Ti-
6Al-4V like, low thermal conductivity, low elastic modulus and chemical reactivity at an
elevated temperature amplify the complications of grinding. High heat generation during
grinding frequently results in the development of residual stresses, surface burn and cracks,
leading to the formation of a subdued surface. A large part of the heat is generated due to high
wheel loading, during which the chips adhere into the intergrit spaces and consequently, blunts
the cutting edges, leading to the greater force and energy requirements for material removal [5-
8]. The problem is exaggerated with the processing of Ti-6Al-4V, as larger wheel loading is
experienced due to its ductile nature.
Application of cutting fluid through effective delivery techniques always helps in increasing
the efficacy of any grinding process [9-12]. However, as dressing is the preliminary operation
to any grinding process, optimizing the dressing process may subsequently enhance the effect
of all the others conditions to follow. Selection of proper dressing parameters and technique
leads to the generation of the favourable topology of the grinding wheel that subsequently,
plays a vital role in the production of superior ground surface [13-14]. The process becomes
more complicated and significant during the handling of the materials with improved
characteristics.
Dressing is a process, performed to improve the grindability of an abrasive wheel by removing
the outermost layer, which becomes loaded and blunt due to its engagement in cutting action,
using a tool that exposes sharp new grits of the wheel from the subsequent layer. Dressing
becomes importantly effective to increase the shearing ability of the cutting wheel and to
minimise the unproductive rubbing and ploughing actions. In their experimental study, Pacitti
and Rubenstein [15] observed that the impact of the dressing tool with the wheel should be
moderate to get better grinding performance as too mild and too strong grinding wheels may
lead to greater grit pull-out and inefficient auto-sharpening phenomenon respectively. Pande
and Lal [16] recommended dressing with higher infeed values to improve tool life. Buttery et
al. [17] and Baseri et al. [18-19] suggested that grinding infeed should be as low as possible if
smoother ground surface is desired. The ambiguity in the relationship of the dressing infeed
and grinding quality is augmented by Klocke et al. [20] and Novák et al. [21] where they found
that optimized dressing infeed values are different for different work-tool combinations. The
problem of finding the optimum dressing infeed for grinding DTM material like Ti-6Al-4V
becomes more potent considering the challenges it offers and in order to improve the
grindability of the material. Mukhopadhyay and Kundu [22] found out the optimum dressing
infeed condition of aluminium oxide wheel for grinding Ti-6Al-4V, where they reported that
grinding using the wheel dressed at 20 µm infeed generates the most satisfactory results for the
aforementioned wheel-material combination.
The literature available raised some serious concerns on the optimized dressing infeed value
for grinding Ti-6Al-4V using a particular type of wheel as machining/grinding behaviour of
any material largely depends upon selected work-tool combination. Furthermore, several
studies showed that optimised dressing behaviour for grinding of a given material varies for
varying the wheel material, in spite of keeping all the other parameters identical [20,21]. The
present experimental investigation focuses, first time, on the performance of SiC wheel for
grinding Ti-6Al-4V in different dressing infeed conditions and consequently, to find out the
optimized dressing infeed. Dry experiments have been performed at different grinding infeed
conditions in order to analyse the effectiveness and consistency of optimised infeed value of
the particular work-tool combination over varying grinding infeed. The effects of differently
dressed wheels are analysed based on the grinding force requirements, grinding ratio, SEM
analyses of the differently dressed wheels and ground substrates, surface roughness parameters,
chip-forms, etc., observed herein.

Materials and Methods

Plunge surface grinding of Ti-6Al-4V is executed on HMT make surface grinder of accuracy
1 µm. Separate identical single point 0.75 carat diamond dressers and SiC wheels have been
employed respectively for each set of dressing infeed condition and experiment to eliminate
experimental uncertainties. Truing of a specific set of wheels is exercised with identical infeed
value as per the intended dressing infeed to eliminate experimental errors associated with it.
Next, the dressing of five identical SiC wheels at different infeed values, viz. 5, 10, 15, 20 and
25 µm are completed with ten consecutive passes at 14 m/min for each set of experiment, while
the cross-feed is kept constant at 1.8 mm/min. For evaluating the performances of the
differently dressed SiC wheels, each wheel has been employed in up grinding of Ti-6Al-4V at
different infeed values of 5, 10 and 15 µm for twenty grinding passes at identical environment.
To ensure dimensional precision, sparking out of the work material is executed before every
grinding operation. Grinding force components are measured during each pass with the help of
a force dynamometer while the wheel wear is estimated using a dial gauge and consequently,
the grinding ratio is evaluated after completion of 20 passes. The forms of the chips, collected
during 20th pass, have been analysed under high resolution microscope and the surface
roughness parameters have been accurately measured using a mechanical type stylus (Surftest
301) at five different regions on the ground surface after 20 grinding passes. The micrographs
of the ground substrate and dressed wheels are captured under Scanning Electron Microscope
(Make: Zeiss, USA, EVO-18) for progressive analysis. All the dressing operations have been
performed keeping the dresser axis perpendicular to the wheel surface as depicted
schematically in Fig. 1. Details of the experimental investigation are represented in table 1.

Figure 1. Schematic of the dressing setup using a single point diamond tool.

Table 1. Experimental details.

Results and Discussion

Ground surface quality has a direct relation with the dressing parameters of the grinding wheel.
Hence, in order to get a superior grinding performance of any material, optimization of dressing
infeed is important. In the present experimental study, the impact of dressing infeed on SiC
wheel for grinding Ti-6Al-4V is analysed. The microstructures of the differently dressed
wheels, observed under SEM are presented in Fig. 2.

Figure 2. SEM micrographs of differently dressed SiC wheels.

These figures clearly indicate the variation in uniformity of the wheel topology with the
variation of dressing infeed. From Fig. 2 (d,e), generation of more uniform edges can be
observed in the wheels dressed at higher infeed values (20 and 25 µm). Similar results were
reported by Mukhopadhyay and Kundu [22] while optimizing dressing infeed for alumina
wheel for grinding Ti-6Al-4V. Furthermore, the intergrit spaces increase with the increase in
infeed values and are found to be maximum in case of the wheels dressed at 20 and 25 µm
infeed values as can be observed from Fig. 2(d,e), providing larger area for the chips to adhere
and consequently, to reduce the detrimental effects of wheel loading. Prominent visual defects
can be observed on the wheel surfaces, dressed with lower infeed values that result in plastic
deformation, leading to the presence of flattened area on the top of the grains. Furthermore,
bond breakage and grit deformation are the effective mechanisms involved during the dressing
process that intensify these phenomena.
The grinding force components have been measured and the variations of average tangential
(Ft) and normal (Fn) force components for 20 passes during each set of experiments are
represented in Fig. 3. From this figure it can be observed that the normal force components are
always greater than their counter parts of tangential force components, which is due to the
involvements of the grits with predominantly negative rake angle in the material removal.
Furthermore, the force requirement increases with the increase in grinding infeed, quite
understandably because of the higher penetration and increase in resistance forces. Force
requirements during grinding using wheels dressed with 5, 10 and 15 µm infeed values are
greater than that of the wheel dressed with 20 µm infeed. This has happened due to the absence
of sufficient intergrit spaces at low dressing infeed values, which can also be observed from
the SEM micrographs as depicted in Fig. 2, promoting wheel loading and high heat generation
that leads to the loss of grit sharpness. In their experimental study, Baseri and his co-workers
[18] also reported high heat generation while grinding with the wheels dressed at lower infeed
values. During grinding at 5 µm infeed using the wheel, dressed with 5 µm infeed, the force is
comparatively found to be low. This may have happened due to the presence of blunt area on
the top of the grains of wheels, resulted due to plastic deformation while grinding with lower
dressing infeed as can be seen from SEM micrograph. This is further prolonged by the bond
breakage and grit deformation, which are the two most likely effects involved during grinding
with the wheels dressed at low infeed values.
From Fig. 3, the general trend can be noticed that the force requirement in every set of
experimentation has decreased with the use of the wheels dressed at higher infeed values. For
example, during grinding of Ti-6Al-4V at 15 µm infeed, the normal force components are
found to be 76.55, 67.75, 65.95 and 52.7 N respectively using the SiC wheels dressed at 5, 10,
15 and 20 µm infeed values. Similarly, the tangential force components are observed as 35.85,
34.1, 33.9 and 26.7 N employing the wheel dressed at 5, 10, 15 and 20 µm infeed values
respectively. It satisfies the previously presented argument of retention of grit sharpness and
intergrit spaces while using wheels dressed at higher infeed values, leading to the removal of
material mainly through shearing mechanism that results in lesser force requirement [22].
Pacitti and Rubenstein [15] stated the condition as the wheel being ‘sharp’, ‘keen’ and ‘open’
thus allowing cutting edges to take effective participation and greater intergrit spaces to refute
the action of wheel loading. However, all the normal and tangential force components
employing the SiC wheel dressed at 25 µm, violate the trends in every set of experimentations
as greater force requirements are found in these cases compared with the corresponding force
requirements while using the SiC wheel dressed at 20 µm. This may be due to the high impact
forces and temperature rise delivered by the dresser as reported by Klocke and Linke [23],
resulting in fragile wheel topology that leads into more bond breakage than that for 20 µm
infeed. Overall force characteristics suggest that using the SiC wheel dressed at 20 µm infeed
has resulted in least force requirements.
Figure 3. Variation of average grinding forces using identical wheels dressed at (a) 5 µm, (b)
10 µm, (c) 15 µm, (d) 20 µm and (e) 25 µm.

Figure 4. Average surface roughness obtained at different infeed values using wheels dressed
at (a) 5µm, (b) 10µm, (c) 15µm, (d) 20µm and (e) 25µm.

Surface quality of the ground substrate is one of the important parameters to evaluate the
performance of the differently dressed wheels. Figure 4 represents the average surface
roughness parameters obtained on the ground surfaces of Ti-6Al-4V using differently dressed
wheels at different grinding infeed values. It can be noticed from this figure that the average
surface roughness parameter increases while using wheels dressed with higher infeed values
during each set of grinding infeed values considered herein. This clearly indicates predominant
shearing actions resulted due to considerably, sharper grits of the wheels dressed at higher
infeed values as can also be seen from Fig. 2. However, the trend is violated during grinding
with the wheel dressed at 25 µm infeed where the surface roughness parameter is found to be
lesser than that is obtained during grinding with the wheel dressed at 20 µm infeed. This may
be due to the high impact forces and temperature rise delivered by the dresser as reported by
Klocke and Linke [23], resulting in fragile wheel topology that leads into more bond breakage
than that for 20 µm infeed. This bond breakage ensues into reduced effective infeed during
grinding, thus limiting the shearing action to some extent. Furthermore, during grinding using
the wheels dressed at lower infeed values, the grits undergo greater glazing and consequently,
polishing action gets established due to the rubbing of blunted grits on the ground surface,
generating considerably smoother surface.
Fig. 5 depicts the micrographs typically of the ground T-6Al-4V surfaces, obtained using
differently dressed wheels while employed at 10 µm grinding infeed. It can be observed from
these figure that the surface qualities obtained during grinding using the wheels dressed at
higher infeed values are superior compared to that, obtained using wheels dressed at lower
infeed values. Presence of surface defects in the ground surface is observed to be lesser while
grinding is performed using SiC wheels, dressed at higher infeed values, indicating positive
effects of improved grit sharpness and increased intergrit spaces that reduces the chances of
heat generation.
Figure 5. Typical micrographs of the ground Ti-6Al-4V surfaces, generated using differently
dressed SiC wheels employed at 10 µm grinding infeed.

Figure 6. Grinding ratio obtained at different infeed values using wheels dressed at (a) 5µm,
(b) 10µm, (c) 15µm, (d) 20µm and (e) 25µm.

Quality of dressing of a grinding wheel has direct impact on the grindability and so on the
grinding ratio. In the present experimental study, the grinding ratios have been calculated
following the estimation of material removal and wheel wear after each 20 passes, and are
depicted in Fig. 6. From this figure it can be observed that grinding ratio has improved with
the use of the wheels dressed at higher infeed values. This is because of the reduction in force
requirements while using wheels, dressed at higher infeed values that results in lesser bond
breakage and grit-pull out. However, using wheel dressed at 25 µm, the grinding ratio has been
found to be lesser compared to that of the wheel dressed at 20 µm. This is due to the higher
force and heat generation during the use of wheel dressed at 25 µm that results into a weakened
surface topology as also reported by Klocke and Linke [23]. This is also supported by the force
values depicted in Fig. 3.
Analysis of the form of the chips collected during grinding may be a basis to evaluate the
performance of the differently dressed SiC wheels. Ti-6Al-4V chips, collected during 20th pass
are observed under stereo microscope and the micrographs are represented in Fig. 7. These
chip-forms are typically obtained using differently dressed wheels while employed at 10 µm
grinding infeed. It can be clearly seen from this figure that the shear type chips are more while
using the wheels dressed at higher infeed values. Grinding with the wheels dressed at low
infeed values shows the presence of more predominantly blocky type chips suggesting higher
wheel loading that has resulted due to considerably lower intergrit spaces and generation of
insufficient cutting edges as can also be noticed from the SEM micrographs.

Figure 7. Typical forms of Ti-6Al-4V chips obtained using differently dressed SiC wheels
employed at 10 µm grinding infeed.

Conclusions
The present experimental investigation is aimed at finding optimum dressing infeed of SiC
wheel for grinding Ti-6Al-4V. Following conclusions can be drawn from the present study.
  Intergrit spaces and uniformity of cutting edges are enhanced with increase in dressing
infeed, and are found to be maximum in case of the wheels dressed at 20 and 25 µm
infeed values.
 The force requirements in every set of experimentation have decreased with the use of
the wheels dressed at higher infeed values. However, employing the wheel dressed at
25 µm, violates the trends while compared with the wheel dressed at 20 µm.  
 Average surface roughness parameters of the ground Ti-6Al-4V surfaces increase while
using the wheels dressed at higher infeed values. However, the trend is violated using
the wheel dressed at 25 µm while compared with wheel dressed at 20 µm.
 Surface qualities obtained using the wheels dressed at higher infeed values are superior.
 Grinding ratio has been improved with use of the wheels dressed at escalated infeed
values. However, using wheel dressed at 25 µm, the grinding ratio has been found to
be lesser compared to wheel dressed at 20 µm.
 Shearing type chips are found employing the wheels dressed at 20 and 25 µm. 

Evaluating and analysing different parameters, it can be inferred that 20 µm is the optimum
dressing infeed of SiC wheel, while grinding Ti-6Al-4V for the operating ranges considered
herein.

Acknowledgements
The authors thank the anonymous reviewers for their comments which led to improvements in
this article.

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9
 Grinding
wheel

90o

Dresser

Figure 1. Schematic of the dressing setup using a single point diamond tool.
(a) wheel dressed at 5 µm (b) wheel dressed at 10 µm

Improved intergrit spaces

(c) wheel dressed at 15 µm (d) wheel dressed at 20 µm

Improved intergrit spaces

(e) wheel dressed at 25 µm

Figure 2. SEM micrographs of differently dressed SiC wheels.

 Grinding infeed
Ft 5 µm Ft 10 µm Ft 15 µm
90 Fn 5 µm Fn 10 µm Fn 15 µm
80

Average Grinding Force (N) 70

60
50
40
30
20
10
0
(a) (b) (c) (d) (e)
Dressing infeed

Figure 3. Variation of average grinding forces using identical wheels dressed at (a) 5 µm, (b)
10 µm, (c) 15 µm, (d) 20 µm and (e) 25 µm.
 (a) (b)
3 (c) (d)
(e) Linear ((a))

2.39
Average Surface Roughness (µm)

2.27
2.5

2.13
1.99
1.87
1.85

1.85
1.77
2

1.38

1.32
1.5

1.11
1.05
1.02
1 0.83
0.7

0.5

0
5 µm 10 µm 15 µm
Grinding Infeed (µm)

Figure 4. Average surface roughness obtained at different infeed values using wheels dressed
at (a) 5µm, (b) 10µm, (c) 15µm, (d) 20µm and (e) 25µm.
 Subdued ground surface
with surface damage

Subdued ground surface

with surface damage

(a)using the wheel dressed at 5 μm (b) using the wheel dressed at 10 μm

Chip re-deposition

Improved ground surface

(c) using the wheel dressed at 15 μm (d) using the wheel dressed at 20 μm

Material pull out

(e) using the wheel dressed at 25 μm

Figure 5. Typical micrographs of the ground Ti-6Al-4V surfaces, generated using

differently dressed SiC wheels employed at 10 µm grinding infeed.
 (a) (b)
(c) (d)
(e) Linear ((a))

0.72
0.8

0.68

0.7
0.63

0.62
0.7

0.59
0.56

0.56
0.53
0.51
0.6

0.49

0.46
Grinding Ratio

0.45
0.43
0.5

0.32
0.4
0.3
0.2
0.1
0
5 µm 10 µm 15 µm
Grinding Infeed (µm)
.

Figure 6. Grinding ratio obtained at different infeed values using wheels dressed at (a) 5µm,
(b) 10µm, (c) 15µm, (d) 20µm and (e) 25µm.
 (a) using the wheel dressed at 5 μm (b) using the wheel dressed at 10 μm

(c) using the wheel dressed at 15 μm (d) using the wheel dressed at 20 μm

(e) using the wheel dressed at 25 μm

Figure 7. Typical forms of Ti-6Al-4V chips obtained using differently dressed SiC wheels
employed at 10 µm grinding infeed.
 Table 1. Experimental details.
 Make: Carborundum Universal Limited,
India
Grinding Wheel
 Specification: CGC 60 K 5 V8

 Make: Norton Abrasives, India

 Specification: 0.75 carat Single Point
Wheel Dresser
Diamond Tip

 Make: HMT, Praga Division, India

Surface Grinding Machine  Spindle Speed: 2880 rpm

 Material: Ti-6Al-4V
 Size: 60mm × 60mm × 6mm
Work Material  Hardness: 33 HRC
 Composition: Ti – 88.77%; Al – 6.19%;
V – 4.25%; Fe – 0.34%

Dressing Environment  Dry

Grinding Environment  Dry

 Make: Sushma Grinding Dynamometer,

Bengaluru, India
Force Dynamometer
 Resolution: 0.1 kg 
 
 Make: Mitutoyo, Japan; Model: Surftest
Surface Roughness Tester 301
 Resolution: 0.05 µm

 Make: Gippon, Japan

Stereo Microscope  Magnification: 20X to 40X

Scanning Electron  Make: Zeiss, USA

Microscope  Serial: EVO-18

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