田辉1， 赵军1，2， 王鼎贺2， 路天霖2， 王栋1， 兰明明1， 李杰3
1.河南农业大学 机电工程学院，河南 郑州 450002； 2.白鸽磨料磨具有限公司，河南 郑州 450000；3.安徽工业大学 冶金工程学院，安徽 马鞍山 243000
引用格式：
田辉， 赵军， 王鼎贺， 等. CBN磨料特性及电沉积工艺对成型磨砂轮性能的调控机制［J］. 中国粉体技术， 2026， 32（4）： 1-12.
TIAN Hui， ZHAO Jun， WANG Dinghe， et al. Regulation mechanisms of CBN abrasive properties and electrodeposition process on performance of form grinding wheels［J］. China Powder Science and Technology， 2026， 32（4）： 1-12.
DOI：10.13732/j.issn.1008-5548.2026.04.016
收稿日期： 2026-01-26， 修回日期： 2025-03-19，上线日期： 2026-04-17。
基金项目： 国家自然科学基金项目，编号： 52074003； 工信部产业基础再造与制造业高质量发展专项，编号： 2023ZY01019。
第一作者： 田辉（1980—），女，教授，博士，硕士生导师，研究方向为功能性材料、智能装备。E-mail：th407@163.com。
通信作者：
兰明明（1984—），男，副教授，博士，硕士生导师，研究方向为材料学。E-mail：lanming@henau.edu.cn。
李杰（1975—），男，教授、博士生导师，研究方向为粉末冶金。E-mail：yejinlijie@163.com
摘要：【目的】探究成型磨用立方氮化硼（cubic boron nitride， CBN）砂轮原材料特性和成型工艺对磨削性能的影响，明确CBN磨料优选标准、电沉积工艺参数的影响机制，为高性能成型磨CBN砂轮制造的工艺优化提供理论支撑和数据依据。【方法】选取6种不同品级的CBN磨料，标记为1#—6#，测试其冲击韧性等核心理化指标；经筛选保留综合性能最优的CBN磨料用于后续电沉积工艺优化及砂轮制备，以电沉积工艺为变量，制备成型磨CBN砂轮；在数控成型磨床上开展HK30粉末冶金磨削试验，采集尺寸精度、表面粗糙度等性能参数；基于正交试验设计，建立CBN磨料特性-电沉积工艺-磨削性能的量化关联模型。【结果】电沉积模式是影响砂轮结合强度的最关键因素，其次为脉冲频率与占空比；经过对6种不同品级CBN磨料的性能筛选，具有高韧性、高晶体完整性的6#磨料综合性能最优，其冲击韧性为47 N，抗压强度的平均值为24 N；电沉积的最优工艺参数为脉冲电沉积模式（频率为500 Hz，占空比为60%），电流密度为0.7 A/dm2，沉积温度为40 ℃，沉积时间为100 min，此条件下砂轮结合强度达310 N，磨粒脱落率仅为2.3%。【结论】CBN磨料的冲击韧性、晶体完整性、抗压强度平均值是影响成型磨砂轮磨削性能的关键指标，CBN中6#磨料为优选原料；优化的脉冲电沉积工艺可显著提升砂轮结合强度与磨粒稳定性，制备的砂轮在尺寸精度、表面粗糙度及磨削寿命方面均优于市售砂轮。
关键词：氮化硼；成型磨砂轮；电沉积工艺；磨削性能
Abstract
Objective Form grinding is a core technology for the high-efficiency and high-precision manufacturing of complex profile parts. Cubic boron nitride (CBN) abrasives are ideal materials for manufacturing form grinding wheels due to their excellent hardness, thermal stability, and wear resistance. The grinding performance of CBN form grinding wheels is jointly determined by the intrinsic properties of the CBN abrasives and the electrodeposition bonding process. However, domestically produced CBN form grinding wheels show unstable performance and short service life due to mismatches between abrasive selection and the electrodeposition process. This study aims to systematically investigate the influence of CBN abrasive characteristics and electrodeposition process parameters on the grinding performance of form grinding wheels, to clarify the optimal selection criteria for CBN abrasives and the influence mechanisms of electrodeposition process parameters, and to provide theoretical support and data basis for process optimization of high-performance CBN form grinding wheels.
Methods Six grades of commercially available CBN abrasives， prepared by a high-temperature and high-pressure (HPHT) method, were selected. Their core physical and chemical properties, including impact toughness (FTI value), thermal shock toughness (FTTI value), single-particle compressive strength, crystal integrity, bulk density, magnetic substance content, and purity, were comprehensively tested and characterized to identify the abrasive with the best overall performance. M238 die steel was selected as the wheel matrix, and HK30 powder metallurgy material was used as the grinding workpiece. A nickel-based electroplating solution was prepared, and the matrix surface was pretreated through oil removal, pickling, and activation. The buried sand method was adopted to achieve uniform adhesion of the CBN abrasives to matrix surface. With electrodeposition mode, pulse frequency, duty cycle, current density, deposition temperature, and deposition time as key variables, orthogonal experiments with 9 groups was designed, and 3 parallel samples were prepared for each group. CBN form grinding wheels were prepared under different process parameters, and grinding tests were carried out on a computer numerical control (CNC) form grinding machine. Range analysis was used to analyze the experimental data, and scanning electron microscopy (SEM) was adopted to observe the micromorphologies of CBN abrasives, electrodeposition coatings, workpiece surfaces after grinding, and abrasive shedding from the grinding wheels. In addition, the grinding performance of the optimized wheel was compared with that of a commercially available direct current (DC) electrodeposited CBN grinding wheel.
Results and Discussion Significant differences were observed in the physical and chemical properties of the six grades of CBN abrasives. The 6# CBN abrasive exhibited the best comprehensive performance, with an FTI value of 47 N, an average single-particle compressive strength of 24 N, a bulk density of 1.79 g·cm-3, a purity of 99.85%, and a magnetic substance content of 0.000 2%. Its crystal structure was complete, with sharp and clear edges and no obvious surface defects, indicating that it was the optimal raw material for preparing high-performance CBN form grinding wheels. Electrodeposition mode was identified as the most critical factor affecting the bonding strength of the grinding wheels, followed by pulse frequency and duty cycle. The bonding strength of DC electrodeposited grinding wheels was consistently lower than 250 N, while pulse electrodeposition refined the grains, reduced internal stress, and improved coating compactness, thus significantly enhancing the bonding strength of the plating layer. The optimal electrodeposition process parameters were determined as follows: pulse mode with a frequency of 500 Hz and a duty cycle of 60%, a current density of 0.7 A/dm2, a deposition temperature of 40 ℃, and a deposition time of 100 min. Under these conditions, the bonding strength reached 310 N, and the abrasive shedding rate was only 2.3%. Grinding performance verification tests showed that the optimized CBN form grinding wheel had a dimensional accuracy of ±0.003 mm, a workpiece surface roughness (Ra) of 0.34 μm, and a grinding life of 337 000 workpieces, which were 9.1%, 10.53%, and 10.85%, respectively, higher compared with the commercially available grinding wheel. Additionally, the abrasive shedding rate was reduced by 25.8%. The synergistic effect of the high-toughness 6# CBN abrasive and the high-holding-force pulse-electrodeposited coating enabled the grinding wheel to resist the initial grinding impact loads, reduce early-stage abrasive shedding and fragmentation, maintain a stable grinding morphology throughout its service life, and inhibit grinding chatter and abnormal abrasive shedding, thus achieving excellent surface quality and dimensional accuracy.
Conclusion The FTI value, crystal integrity, and average compressive strength are key indices affecting the grinding performance of CBN form grinding wheels, and the 6# CBN abrasive is the preferred raw material for manufacturing high-performance CBN form grinding wheels. The optimized pulse electrodeposition process significantly improves bonding strength and abrasive retention stability. The prepared grinding wheels exhibit significant advantages in dimensional accuracy, surface roughness, abrasive shedding rate, and grinding life compared with commercially available DC electrodeposited CBN grinding wheels. This research establishes a quantitative correlation model of CBN abrasive characteristics, electrodeposition process, and grinding performance, which provides an important experimental basis and technical support for the independent manufacturing and engineering application of high-performance CBN form grinding wheels.
Keywords：boron nitride; form grinding wheel; electrodeposition; grinding performance
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