MSc.Thesis Defense:Seyedeh Suzan Behrouz Baraghi

SIMULATION AND MANUFACTURING OF METAL BRAZED CBN GRINDING TOOLS

Seyedeh Suzan Behrouz Baraghi
Mechatronics Engineering, MSc. Thesis, 2024

Thesis Jury

Prof.Erhan Budak(Thesis Advisor),

Assoc. Prof. Bekir Bediz,

Assoc. Prof. Umut Karagüzel

Date & Time: December 20th, 2024 –  10:30 AM

Place: FENS L065

Keywords : Brazing, Patterned Tool, CBN Tool, Grinding

Abstract

Brazing with Ti-bronze bonding material is explored as a transformative method for manufacturing advanced cubic boron nitride (CBN) grinding tools, addressing challenges like grit distribution, material compatibility, and oxidation. Process optimization, including a controlled atmosphere, resulted in a 19–21% reduction in grinding forces and a 25–27% drop in workpiece temperatures compared to conventional tools, while maintaining acceptable surface roughness. Finite element analysis (FEA) validated bonding strength and thermal dissipation capabilities, offering insights into thermal-mechanical stability. Laser ablation was investigated as a complementary technique, improving chip evacuation and cooling via structured patterns, leading to further reductions in grinding forces (22–25%) and temperatures (28–30%). A digital twin framework optimized these processes, predicting performance metrics and minimizing material waste. While laser ablation enhanced performance, brazing emerged as a more cost-effective solution, particularly for moderate surface finish applications. The combined experimental results, FEA, and digital twin modeling provide a comprehensive understanding of grinding tool performance, paving the way for further process refinements and sustainable, high-precision manufacturing.