LAUSR

ABSTRACT In the present work, the effect of various grinding mechanisms on white layer (WL) formation in AISI 52100 steel is studied using two types of alumina grains, one produced by sol–gel process and the other by conventional fusion. Further, a novel approach is proposed on predicting the WL formation using grinding power. This study correlates the power variation with the change in the metallurgical aspects of the work material. WL of about 56 µm thickness is observed in the material ground by worn out sol–gel alumina wheel. However, no WL is present in the material ground by fused alumina wheel. High toughness in sol–gel alumina led to generation of wear flats with increasing grinding passes and transformed the dominant grinding mechanism from shearing to plowing and sliding. This increases the temperature in the grinding zone, which was the reason for WL formation. Change in the dominant grinding mechanisms from shearing is found to increase the grinding power. Since the change in dominant grinding mechanisms is the cause for WL formation, the increase in grinding power is found to be a good measure in predicting the WL formation. The predictability of WL formation by grinding power is further validated by comparing the power variation in grinding process by both the grinding wheels.