Comprehensive Analysis of Titanium Alloy Machining with 2–7% Carbon Nanotube-Infused Cubic Boron Nitride Grinding Wheel Utilizing Full-Factorial Design

This research explores the experimental analysis of titanium alloy using an innovative approach involving a 2–7% carbon nanotube (CNT)-infused cubic boron nitride (CBN) grinding wheel. Employing a full-factorial design, the study systematically investigates the interactions among varied wheel speed, workpiece feed rate, and depth of cut, revealing compelling insights. The integration of CNTs in the CBN grinding wheel enhances the machining performance of titanium alloy, known for its high strength and challenging machinability. The experiment varies CNT infusion levels to assess their impact on material removal rate (MRR) and surface finish. Significantly, MRR is influenced by CNT content, with 5% and above demonstrating optimal performance. The 7% CNT-CBN wheel exhibits a remarkable 61% improvement in MRR over the conventional CBN wheel. Interaction studies highlight the pivotal role of depth of cut, indicating that slower speeds and feeds, combined with increased depth of cut, enhance abrasive grit penetration and produce superior surface finishes. The damping coefficient, reflective of wheel strength and longevity, follows the MRR trend, with the 7% CNT-CBN wheel displaying the highest value. SEM and AFM images confirm improved surface finishes and reduced grinding burns. This study presents a novel strategy for studying the MRR and Ra while grinding titanium alloy with CNT-infused grinding wheels, offering valuable insights for the field.