Electrochemical superabrasive machining of a nickel-based aeroengine alloy using mounted grinding points

Brief design and manufacture considerations are detailed for a hybrid electrochemical grinding unit adapted from a vertical machining centre using a 40,000 rpm spindle and 500 A DC generator. Subsequently, experimental work is presented on the influence of tool bond systems, superabrasive grit type and electrical parameters when simultaneous ECM/grinding Udimet 720 using 10–15 mm diameter plain points. Single layer electroplated CBN tools produced G-ratios and maximum normal cutting forces of ∼451 and ∼45 N, respectively, compared to ∼128 and 557 N for equivalent diamond wheels. Data on workpiece roughness and overcut are also presented as are initial results for a fir tree shaped tool.