Mechanistic design of porous self-lubricating grinding wheels with integrated internal cooling: Role of PMMA and nickel-coated MoS₂ composites in machining enhancement

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology Pub Date : 2025-04-30 DOI:10.1016/j.jmatprotec.2025.118877

Linfeng Zhao , Ruitao Peng , Jiangxiong Gao , Yibo Li , Min Chen

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引用次数: 0

Abstract

This study significantly advances grinding wheel technology by synergistically integrating poly (methyl methacrylate) (PMMA)-induced porosity with nickel-coated molybdenum disulfide (Ni-coated MoS₂) lubrication. This integration addresses the critical trade-off between cooling efficiency and structural durability in grinding nickel-based superalloys. Mechanistic analysis indicates that sintering at 910°C allows nickel to suppress copper-sulfur interfacial embrittlement while promoting titanium carbide (TiC) bonding reinforcement. This process achieves an optimal flexural strength of 72.63 MPa with 5 % PMMA-induced interconnected porosity. The pore network enhances coolant retention, resulting in an 18.6 % reduction in grinding temperature through a combination of internal cooling and lubricant film dissipation. Tribological optimization at 6 % Ni-coated MoS₂ content reduces friction coefficients by 22.7 % under a 100 N load due to lattice distortion effects, while also mitigating abrasive adhesion through controlled solid lubricant release. Comparative grinding trials demonstrate transformative performance: surface roughness decreases by 30.45 % as porous channels retain grinding debris, thereby suppressing three-body abrasion. Additionally, compressive residual stresses increase twofold due to reduced thermal gradients. Crucially, the self-sharpening mechanism extends wheel longevity by maintaining the integrity of abrasive protrusions compared to conventional wheels, as validated by reduced microcracking and spalling observed in post-test microscopy. These advancements establish a material-process paradigm in which controlled porosity generation synchronizes thermomechanical stress management with tribological regulation, achieving simultaneous improvements in surface quality, thermal control, and grinding wheel lifespan for machining applications.

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集成内冷却多孔自润滑砂轮的机械设计：PMMA和镀镍MoS 2复合材料在加工强化中的作用

该研究通过将聚甲基丙烯酸甲酯（PMMA）诱导孔隙与镀镍二硫化钼（Ni-coated MoS 2）润滑协同结合，显著推进了砂轮技术。这种集成解决了在磨削镍基高温合金时冷却效率和结构耐久性之间的关键权衡。机理分析表明，910℃烧结可抑制铜硫界面脆化，同时促进碳化钛（TiC）结合强化。该工艺的最佳抗弯强度为72.63 MPa， pmma诱导的互连孔隙率为5 %。孔隙网络增强了冷却剂的保留，通过内部冷却和润滑膜消散的结合，使磨削温度降低18.6 %。当Ni-coated MoS 2含量为6 %时，在100 N载荷下，由于晶格畸变效应，摩擦系数降低了22.7 %，同时通过控制固体润滑剂的释放也减轻了磨料的粘附性。对比磨削试验表明，由于多孔通道保留磨削碎屑，表面粗糙度降低了30.45 %，从而抑制了三体磨损。此外，由于热梯度的减小，压缩残余应力增加了两倍。至关重要的是，与传统车轮相比，自锐机制通过保持磨料突起的完整性来延长车轮寿命，正如测试后显微镜观察到的减少微裂纹和剥落所证实的那样。这些进步建立了一种材料工艺范例，在这种范例中，可控孔隙率的产生与摩擦学调节同步进行热机械应力管理，同时改善了加工应用的表面质量、热控制和砂轮寿命。

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来源期刊

Journal of Materials Processing Technology 工程技术-材料科学：综合

CiteScore

12.60

自引率

4.80%

发文量

403

审稿时长

29 days

期刊介绍： The Journal of Materials Processing Technology covers the processing techniques used in manufacturing components from metals and other materials. The journal aims to publish full research papers of original, significant and rigorous work and so to contribute to increased production efficiency and improved component performance. Areas of interest to the journal include: • Casting, forming and machining • Additive processing and joining technologies • The evolution of material properties under the specific conditions met in manufacturing processes • Surface engineering when it relates specifically to a manufacturing process • Design and behavior of equipment and tools.