Technological Reserves of Improving Grinding Quality of High Speed Steel Plates with Improved Productivity

This study identifies methods of improving the quality of R9M4K8 and R12F3K10M3 high-speed steel plates, the use of which in tool manufacturing is restricted by their low grindability. The roughness parameters Ra and Rmax (GOST 2789–73) and flatness deviation parameters (GOST 24642–81), namely the basic parameter EFEmax and the supplementary parameters EFE_a и EFE_q, called the arithmetic and quadratic indexes respectively, are accepted as the output grinding parameters. The Norton 5SG46K12VXP high-porous wheel (HPW) is chosen as an abrasive tool. Its sintercorundum grains have an improved cutting capacity compared to traditional electrocorundum, namely 34AF60K6V5 alloyed chrome.  The capabilities of high-porous sintercorundum wheels are shown at the spark-out stage using the non-parametric statistics method, which has advantages compared to parametric evaluations when the conditions of homoscedastic and normalcy distribution are violated. Univariate distributions of frequencies by medians have shown that sparking-out of the high-speed plate provides the most significant decrease of median flatness deviation (up to 1.25–1.3 times), with the spark-out pass j = 6 for the R9М4К8 plate, and j = 8 for the R12F3К10М3 plate. For the R12F3К10М3 plate, the parameter Rmax is decreased by one categorical magnitude (CM) according to GOST 2789–73, and the parameter R_a is decreased within the CM range. For the R9М4К8 plate, the heights Ra and Rmax are characterized by the values 0.05 and 0.32 mcm respectively, and lie in the range of CM. The specified number of spark-out passes is also taken into consideration when the accuracy of the process is assessed.

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