International Journal of Machine Tools & Manufacture 42 (2002) 585–593

Precision grinding using CBN wheels

a,*
X. Chen , W.B. Rowe b, R. Cai b

a
School of Mechanical, Materials, Manufacturing Engineering and Management, University of Nottingham, Nottingham NG7 2RD, UK
b
School of Engineering, Liverpool John Moores University, Liverpool L3 3AF, UK

Received 29 March 2001; received in revised form 12 October 2001; accepted 16 October 2001

Abstract

The paper systematically reviews experimental research on the performance of cubic boron nitride (CBN) grinding wheels and
discusses advantages and difficulties experienced in the application of CBN wheels particularly for internal grinding with fine-
grain wheels.
The hardness of CBN grains potentially increases re-dress life and improves dimensional stability. The problem is that increased
re-dress life increases the importance of avoiding wheel loading, particularly for small-grain wheels. This paper highlights the
importance of touch dressing for improved dimensional stability and other operational techniques to maintain an open surface
topography of the wheel. The paper also demonstrates the benefit of an open-structured small-grain CBN wheel for precision
grinding. Effects on grinding temperature are also illustrated.  2002 Elsevier Science Ltd. All rights reserved.

Keywords: Grinding; CBN; Precision; Dressing

1. Introduction are much more expensive than conventional wheels

Cubic boron nitride (CBN) grinding wheels have been
used by industry for a few decades, often with very good
results. The advantages of CBN grinding are gradually
becoming a consensus. However, there are still chal-
lenges to realise the advantages of CBN grinding in
industry [1]. Optimal CBN grinding requires a system-
atic approach taking account of all relevant factors. This
paper reviews a number of these factors and shows how
the process may be influenced in practice.
Because CBN grains are much harder than aluminium
oxide (Al2O3) and silicon carbide (SiC) grains, CBN
wheels have greater wear resistance than conventional
wheels. Consequently, a CBN wheel usually gives better
size holding and longer wheel redress life. The high ther-
mal conductivity of CBN abrasives provides an advan-
tage of cooler grinding compared with conventional alu-
minium oxide wheels or silicon carbide wheels. This
allows much higher removal rates without thermal dam-
age or tensile residual stress. Against this, CBN wheels
* Corresponding author. Tel.: +44-115-951-14015; fax: +44-115-
951-4000.
E-mail address: xun.chen@nottingham.ac.uk (X. Chen).
where the wheel cost may be almost negligible. With
conventional internal grinding wheels, costs which may
be more significant include costs of downtime due to
more frequent wheel changing, set-up costs and more
frequent re-dressing costs.
Vitrified bonded CBN wheels have different charac-
teristics from conventional wheels. The mechanical
strength of vitreous bonds for CBN abrasives is usually
much higher compared to conventional wheels of the
same grain size. This is because CBN wheels are
designed to have a lower wear rate and it is important
that the grains are not easily lost by breaking away from
the bond. Also, the size of selected CBN grains is usu-
ally smaller than that of conventional wheels for the
same grinding task. This feature allows low surface
roughness to be achieved with sharp CBN grains. All
these features provide CBN wheels with a different per-
formance from conventional wheels.
The force required for a dressing tool to cut through
CBN grains is high because of high CBN hardness. The
force often pulls out rather than cuts through grains,
leaving bond material on the wheel surface. In such
cases, the initial grinding is conducted with the bond
material as much as with the grains. For CBN grinding
a common situation that results is that grinding power

0890-6955/02/$ - see front matter  2002 Elsevier Science Ltd. All rights reserved.
PII: S 0 8 9 0 - 6 9 5 5 ( 0 1 ) 0 0 1 5 2 - 3
586 X. Chen et al. / International Journal of Machine Tools & Manufacture 42 (2002) 585–593

Nomenclature
a1 grinding depth for each wheel travel pass
ad dressing depth
b grinding width
C constant
cw specific heat capacity
fd dressing lead
kg effective thermal conductivity of abrasive grains
le real contact length
ltr wheel traverse distance
nd dresser rotational speed
ns wheel rotational speed
nw workpiece rotational speed
P grinding power
q average heat flux
r0 effective wear flat contact radius
Rw partition ratio of heat flux into the workpiece to the average heat flux
Rws energy partition ratio between workpiece and wheel grain
Tsmax maximum surface temperature
vs wheel speed
vtr wheel traverse speed
bw coefficient of heat diffusion
␬w workpiece thermal conductivity
rw workpiece density

after initial dressing may be very high so that it may be
difficult or impossible to grind. If satisfactory grinding
is achieved, the power decreases towards a steady value,
as grinding proceeds. The initial higher power is mainly
attributed to the flattening of the CBN wheel surface [2].
Efficient grinding only takes place after the bond
material at the wheel surface has been eroded so that the
grains protrude from the bond. A conditioning process
is often introduced to avoid grinding damage to work-
pieces. The conditioning process may involve grinding
at a reduced rate or the use of a conditioning stick. The
conditioning process decreases productivity.
The high hardness of CBN abrasives leads to different
wear behaviour compared with conventional abrasives.
CBN wheels do not have the self-sharpening effect that
is a common feature of conventional grinding wheels.
Therefore, opening up a CBN wheel surface to achieve
an effective cutting surface is vital for effective CBN
grinding. Special techniques may be required for effec-
tive CBN grinding involving high-porosity wheels for
difficult-to-grind materials, increased wheel speeds, spe-
cial dressing techniques and coolant delivery systems.
The advantages of CBN grinding can only be realised
when all relevant factors are controlled. This normally
involves a proper selection of dressing and grinding con-
ditions and efficient coolant delivery. To improve CBN
grinding, all facts involved should be considered com-
prehensively.
2. Factors influencing a grinding process
Systematic consideration of a grinding process
requires knowledge of inputs and outputs from the grind-
ing process. A grinding process is a material removal
process utilising a grinding wheel, which is made up of a
large number of randomly positioned grains. The grains
subsequently penetrate the workpiece to remove the
material in front of their path. Understanding the grind-
ing process starts from the material removal by individ-
ual grains. The material removal process progresses
through the stages of sliding, ploughing and cutting. If
the grains are dull, the process will be dominated by
inefficient sliding and ploughing phases of grain interac-
tion rather than the efficient cutting phase.
Focusing on grain interactions, the relationship
between influential parameters can be summarised as in
Fig. 1 [3]. The factors in the top layer are the primary
inputs to a grinding process and the outputs are listed at
the bottom. The environment includes the atmosphere
and also the fluid delivery, both of which are very
important from a lubrication viewpoint. The environ-
ment also includes the machine structure.
The grinding system behaviour is considered prim-
arily from the viewpoints of geometry, kinematics,
mechanics, energy and material properties. The perform-
ance of a precision grinding wheel is usually assessed
using force, vibration, temperature, and roughness. A
 X. Chen et al. / International Journal of Machine Tools & Manufacture 42 (2002) 585–593
Fig. 1. A systematic view of inputs and outputs of a grinding process.
good grinding wheel, correctly dressed, presents low
force and temperature, specified workpiece integrity,
consistent accuracy and specified surface roughness.
Large variations in grinding behaviour are not accept-
able.
Actual grinding performance can be considered as the
summation of the performance of individual grains.
Based on the relationships illustrated in Fig. 1, improve-
ment and stabilisation of the grinding performance may
be achieved by considering grinding wheel surface top-
ography, chip formation and materials properties as well
as the grinding environment, including machine struc-
ture, coolant delivery, and so on, as illustrated in the
following results.
3. Touch dressing technique
Dressing parameters for conventional wheels when
applied to CBN wheels are far from ideal. After dressing,
the grinding force is very high and removal rates are
reduced unless an appropriate conditioning technique is
employed to “open up” the wheel. Fig. 2 shows grinding
results using an 11 mm diameter CBN internal grinding
wheel to grind a 50 mm bore. The grinding power after
conventional dressing takes a long time to decrease from
an initial high value to an acceptable steady lower value.
The total power decrease is about one-third of the initial
power. The high initial grinding power is attributed
mainly to the flattening of the CBN wheel surface with
conventional dressing. Because of the high hardness of
CBN, the force required for the dresser to cut through
587
Fig. 2. Grinding power with a conventional dressing operation.
the CBN grains is high. If the dressing depth is large, the
large dressing force may pull out grains, leaving bond
material at the wheel surface. The subsequent grinding
is then conducted with bond material as well as with
grains. This is equivalent to grinding with a blunt wheel
which increases rubbing and reduces cutting. Effective
grinding only takes place after bond material at the
wheel surface is worn away so that only grains are used
for grinding.
Fig. 3 illustrates schematically how a large dressing
depth closes up the wheel surface. If grain pullout is
considered, the wheel surface will be even worse. If the
dressing depth is reduced, as in the case of touch dress-
ing, the dresser may cut through the grains without pull-
ing them out, leaving sharp grains on a more open wheel
surface. Therefore, a lower initial grinding power is
expected.
Touch dressing is a technique of dressing a vitrified
CBN grinding wheel with a minimal dressing depth
(usually less than 5 µm) so that the correct profile of the
wheel is restored without loss of cutting ability. Fig. 4
shows how a touch dressing operation gives a lower
initial grinding power. It can also be seen that the vari-
ation in grinding power for touch dressing is less than
for conventional dressing, which means that the grinding
Fig. 3. A large dressing depth of cut closes up the wheel surface.
588 X. Chen et al. / International Journal of Machine Tools & Manufacture 42 (2002) 585–593
Fig. 4. Grinding power under touch dressing conditions.
performance is more stable. Fig. 5 also confirms that the
grinding performance with touch dressing is more stable
than that with normal dressing. The surface roughness
with normal dressing conditions is doubled during a re-
dressing cycle while the surface roughness with touch
dressing remains at a similar level. The decrease in the
dressing depth increases the usable wheel life. The con-
sumption of the wheel using touch dressing is less than
one-third of that with normal dressing conditions. The
improvements clearly demonstrate the potential of touch
dressing to reduce the cost of grinding.
Fig. 5. Variation of surface roughness under different dressing con-
ditions.
Measurements of a wheel surface illustrated in Fig. 6
demonstrate the effects of different dressing depths on
a wheel surface. A helix feature is evident on the wheel
surface using a large dressing depth. It can be seen that
a large dressing depth leaves fewer cutting edges on the
wheel surface to engage with the workpiece. The grain
cutting depth in precision grinding is less than 1 µm. A
small dressing depth provides more grains to carry out
grinding immediately after dressing so that more
efficient grinding can be achieved from the start.
For conventional dressing, the dressing lead plays a
very important role in opening up the wheel surface
because of the helix feature. The large dressing lead nor-
mally gives a more open surface, but the ground compo-
nent surface roughness will be greater. The dressing lead
is restrained by the surface finish requirement. For touch
dressing, the dressing mechanism is changed. Either the
wheel structure itself or erosion during grinding creates
the space between the grains on the wheel surface. The
requirement in touch dressing is to ensure that every
grain is re-sharpened by dressing, not to remove large
numbers of grains from cutting and not to reduce the
number of active cutting edges since this would increase
roughness. A larger dressing lead is employed which is
still sufficient to dress all the cutting edges. The previous
slow dressing lead damages the cutting edges by
repeated contacts. The larger dressing lead greatly
reduces the time for a dressing pass and therefore
increases productivity. It can be seen from Figs. 2 and
4 that the touch dressing is much faster than the conven-
tional dressing.
The main challenge in applying touch dressing is how
to determine the initial contact between the dressing tool
and the wheel and how to achieve a small constant dress-
ing depth of cut of less than 5 µm. A CNC (computerised
numerical control) machine has the ability to position a
machine axis to a high accuracy and to achieve an
increment of 1 µm. However, although modern CNC
systems can position the dressing tool to a high accuracy,
there is still a requirement to detect the position of the
grinding wheel surface. The position of the grinding
wheel surface relative to the machine axis positions
changes continually due to grinding wheel wear, thermal
expansion of the machine tool and thermal expansion or
contraction of the grinding wheel. Diamond wear also
changes the position of the diamond dressing tool. The
effect of this variability is that the wheel position stored
in the CNC is inaccurate by the time it is necessary to
re-dress the grinding wheel. To overcome this problem
the machine user often specifies a large dressing infeed
to guarantee that the dressing tool will dress the grinding
wheel. An alternative strategy is to estimate the mean
grinding wheel wear rate and use this within the CNC
to adjust the required dressing increment. The latter
strategy relies on the grinding wheel wear rate being
 X. Chen et al. / International Journal of Machine Tools & Manufacture 42 (2002) 585–593
Fig. 6. Wheel roundness measurement shows that touch dressing provides more grains on the wheel surface: (a) dressing depth is 10 µm; (b)
dressing depth is 3 µm.
constant. For workpieces with varying stock allowance
this strategy will fail.
A better strategy is to detect the initial contact
between the grinding wheel and the dressing tool and
then apply the required dressing increment. Acoustic
emission (AE) sensors are used for this purpose [4].
Acoustic emission is employed because the high-fre-
quency signals of dressing contact can be discriminated
from background noise. The acoustic emission from the
contact between the dresser and the abrasive grains con-
tains some very high-frequency harmonic elements. The
AE signal is characterised using a band-pass filter, a rec-
tifier and a low-pass filter. Initial trials on an external
grinding machine showed that the detection of dressing
depths of cut of 1 µm are easily achieved on an external
grinding machine.
However, detection of contact between the dresser and
the wheel for a high-frequency internal grinding machine
was found to be difficult because of the much higher
frequency of the background noise. The high-frequency
components are attributed to harmonics of the high speed
of the grinding wheel spindle and the motor-driven
rotary dressing cup. The signals to be monitored for
touch dressing should be in a higher frequency range
than the background noise to give a satisfactory signal-
to-noise ratio. High-frequency AE signal energy is heav-
ily reduced during its transfer to the sensor. For an AE
sensor mounted on the body of the rotary dressing tool,
the AE signal is required to pass from the dressing tool
to the sensor via the dressing tool shaft, the support bear-
ings and the dresser body. In Fig. 7, for example, it is
not clear when the dresser touched the wheel, even
though the dressing depth was 10 µm.
To reduce the transmission distance and the number
of elements in the transmission path, a coolant coupling
method was used. This method allowed the transfer of
a much stronger contact AE signal to the sensor. The
AE sensor mounting position is shown in Fig. 8. The
AE signal travels directly to the AE sensor via the cool-
ant. Fig. 9 shows that AE signals were greatly improved
589
using the coolant coupling method. A 1 µm dressing
depth can be easily identified. The amplitude of the high-
frequency components of the AE signal remain at a
higher level and can be distinguished from the back-
ground noise. Based on the ability to detect a 1 µm
dressing depth using an AE sensor, the trueness of the
grinding wheel shape can also be monitored. This may
provide a new method for monitoring the grinding
wheel shape.
4. Achieving an open wheel surface
The workpiece materials ground have a strong tend-
ency to adhere to the wheel cutting surface causing a
condition known as “loading”. Workpiece material
accumulates on the wheel surface, blocking the space
between the grains and attaching near the tips of the
grains. Even with slight loading, workpiece roughness is
increased. With severe loading, the cutting ability of the
grinding wheel rapidly deteriorates causing high grind-
ing forces and high temperature leading to grinding burn.
Furthermore, it may cause catastrophic failure of the
grinding wheel. The wheel may explode within a few
seconds because of severe wheel loading. Caution should
therefore be taken to prevent grinding chip loading.
Therefore, keeping the wheel surface clean is important
for satisfactory grinding. There are several ways of seek-
ing to prevent loading and the results of the investigation
are discussed as follows.
One way to restore a clean wheel surface is to remove
the loaded layer by re-dressing. This is an expensive
option. Frequent dressing of a CBN wheel is to be avo-
ided because of the high cost of CBN abrasives and the
reduction in cutting efficiency described previously. In
grinding, the workpiece material may be loaded into the
wheel surface to a depth of considerably more than 10
µm. The loaded layer will not therefore be removed in
one dressing pass using touch dressing. This means that
more of the abrasive layer is wasted to achieve a clean
590 X. Chen et al. / International Journal of Machine Tools & Manufacture 42 (2002) 585–593

Fig. 7. AE contact signal merged by high-frequency environmental noise.

Coolant delivery is another important aspect to be

considered. Coolant delivery not only washes out debris
but also provides lubrication and cool grinding. If cool-
ant is not properly delivered into the grinding zone, the
grinding wheel is much more likely to become loaded.
Fig. 10 shows severe wheel loading due to inadequate
coolant delivery. Chips are compressed and adhered into
the space between grains, which causes poor grinding
performance and the workpiece material can be seen to
adhere to the outer surface of the grains.
In order to prevent wheel loading, an elevated press-
ure (4 bar) coolant delivery system for internal grinding
was investigated. The coolant delivery is illustrated in
Fig. 11. The system included a higher-pressure low-vol-
ume coolant supply for wheel cleaning and a lower-
pressure high-volume coolant delivery for lubricating
and cooling the grinding process. By using this arrange-
ment of coolant delivery, the stability of the grinding
wheel performance was improved. It is possible that
Fig. 8. Arrangement of a coolant coupling device for AE sensing. much higher pressures could be an advantage, although
this was not investigated.
The third solution to prevent loading is to employ an
open wheel structure to help coolant delivery to the

Fig. 9. Improvement of AE contact signals using a coolant coup-

ling method.

wheel. Under these conditions the benefit of touch dress-

ing will not be realised. To reduce excessive wheel con-
sumption, wheel loading must be prevented in the first
place. Fig. 10. A heavily loaded wheel surface.
 X. Chen et al. / International Journal of Machine Tools & Manufacture 42 (2002) 585–593
Fig. 11. A coolant delivery system for CBN internal grinding.
grinding zone and provide more space to accommodate
the swarf produced in grinding. This approach proved to
be especially effective for difficult-to-grind workpiece
materials such as Inconel 718.
The grinding performance of a high-porosity fine-
grain CBN wheel is compared with the grinding per-
formance of a more conventional structure fine-grain
CBN grinding wheel. The tests were conducted using
the previously optimised touch dressing process and the
higher pressure coolant delivery system. The conven-
tional structure wheel failed to grind Inconel 718 at a
wheel speed of 50 m/s due to heavy loading after a spe-
cific material removal of 60 mm3/mm, whereas under
the same specific material removal, the high-porosity
fine-grain wheels gave a good grinding performance
with a G ratio of 2000, an average surface roughness Ra
of 0.18 µm and a wheel re-dress life of 500 mm3/mm
before the acceptable roughness was exceeded. The
grinding performance of the high-porosity fine-grain
wheel was even better when the wheel speed was
increased from 50 to 60 m/s. The G ratio increased to
Fig. 12. Performance of a high-porosity CBN grinding wheel used to grind Inconel 718.
591
4000, Ra decreased to 0.13 µm and the wheel re-dress
life increased to 1400 mm3/mm. The results are illus-
trated in Fig. 12, which demonstrates that ideal precision
grinding would use a high-porosity fine-grain wheel
under a high grinding speed. A similar approach has
been tried in a superfinishing process [5].
5. Temperature control
A high temperature is generally undesirable because
it introduces grinding burn and tensile residual stresses.
Recent research demonstrated that there is a transitional
boundary for grinding-induced residual stresses [6]. The
boundary is influenced by material properties and can
be represented by the grinding temperature. For a given
material, tensile residual stresses can be prevented if the
grinding temperature does not exceed the transitional
temperature. The rise in the workpiece temperature
depends mainly on how much of the energy generated
by the grinding enters the workpiece. The more energy
enters the workpiece, the higher is the temperature rise.
If the proportion of grinding heat to the workpiece is
known, then the maximum surface temperature Tsmax can
be determined from [7]:
冪v
CRwq le
Tsmax⫽ (1)
bw w
where Rw is the ratio of the heat going into the workpiece
to the total heat generated in the grinding zone, bw is
the coefficient of heat diffusion of the workpiece, le is
the real contact length and C is a constant of value 3.3
to 3.5. The mean total heat flux in the grinding zone is
P
q⫽ (2)
leb
where P is the grinding power for the particular grinding
592 X. Chen et al. / International Journal of Machine Tools & Manufacture 42 (2002) 585–593
conditions and b is the grinding width. The coefficient
of heat diffusion of the workpiece is defined as
bw⫽冑␬wrwcw
(3)
where ␬w is the thermal conductivity of the workpiece,
rw is its density and cw its specific heat capacity. ␬w and
cw vary with temperature. However, it is found that the
variation of bw with temperature is much smaller, usu-
ally less than 5%. An average value [6] for the tempera-
ture range up to 600°C for the particular workpiece
material (0.5% carbon steel) can be assumed to be
13 540 J/(K m2 s1/2).
It is important to know the proportion of the grinding
energy that goes into the workpiece for the determination
of the grinding temperature. The energy in grinding is
initially dissipated within the grinding zone to four heat
sinks. These are the wheel, the chips, the fluid and the
workpiece. The largest proportion of the grinding heat
usually, but not necessarily, goes into the workpiece.
The proportions to each of the four heat sinks depend
on the grinding conditions and the thermal properties of
the materials. Heat, as it is generated at the grain contact,
is initially shared between the chips, the grains and the
workpiece. The temperature of the chips is known to be
very high but is usually less than the melting tempera-
ture. The energy carried away by the chips is therefore
approximately equal to the melting energy. The remain-
ing energy going into the workpiece depends on the
energy partition ratio Rws between the workpiece and
wheel grains, which can be expressed as:
1 ␬g
⫽1⫹ (4)
Rws (r0vs)1/2bw
where r0 is an effective wear flat contact radius, vs is the
wheel speed, and ␬g is the effective thermal conductivity
of the CBN grains. It is reported [8] that ␬g is 37 W/mK
for alumina and 240 W/mK for CBN. These data show
that CBN has a much higher thermal conductivity than
alumina. Experiments showed that the partition ratio of
the heat flux into the workpiece to the average total heat
Fig. 13. Difference in grinding temperature between CBN grinding
and conventional grinding.
flux Rw is typically 70–80% for alumina and 40–50%
for CBN [9]. This means that less energy goes into the
workpiece for CBN grinding and a CBN wheel provides
cooler grinding. Fig. 13 shows that CBN grinding is
cooler than conventional grinding.
6. Size stability
Owing to the high hardness of CBN, which is more
than twice that of a conventional abrasive, CBN grinding
demonstrated better wear resistance. It was possible to
grind for a much longer period with CBN before
exceeding the tolerance on size variation. To achieve
better size stability, a suitable dressing strategy should
also be used to obtain stable wheel sharpness [10,11].
7. Conclusion
The very high hardness of CBN abrasives provides
better size-holding ability for the CBN grinding. The
high thermal conductivity of CBN allows cooler grind-
ing or a much higher removal rate. CBN grinding also
reduces the occurrence of tensile residual stresses. To
achieve efficient and stable CBN grinding, a systematic
approach should be applied. An individual factor change
may not provide substantial improvement. As described
in this paper, the benefit of the hardness of CBN can
only be achieved through simultaneously applying sev-
eral advanced techniques, such as touch dressing and
better coolant delivery. For difficult-to-grind materials,
it may also be necessary to employ high-porosity CBN
wheels. It is shown that touch dressing improves the
stability of grinding. For high-frequency internal grind-
ing, fluid coupling allows greater sensitivity and accurate
transmission of AE signals to the sensor. A saving of
grinding cost may be achieved by reducing the wheel
consumption and the dressing time. By employing touch
dressing, longer wheel life, reduced variation of grinding
performance and more uniform quality of ground work-
pieces can be expected. For CBN grinding, the potential
cost saving is obvious.
Acknowledgements
Acknowledgements are due to EPSRC, Dittel,
Jones & Shipman, RollsRoyce, Wendt Boart, and
Timken (Europe) for project support.
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