Manufacturers face challenges when dealing with abrasives that lose roundness,wear excessively,and suffer from pitting of the surface of the grinding wheel that needs rectification using dressing techniques.Nanostructured abrasive grits manufactured by hybrid fusion processes and by sintering/extrusion/printing processes are found to reduce pitting quite significantly.The phenomenon of wheel collapse is increasing and cycle times developed during the grinding of aerospace alloys are much smaller compared to using conventional materials.This paper reviews the phenomenon of wheel collapse induced by pitting and takes a critical look at the production and analysis of hybrid fused and printed/sintered abrasives.A mathematical analysis is carried out of the diffusion of primary and secondary phases due to mechanical and ultrasonic agitation with the aim of producing abrasive grits with improved strength and retention.Current developments in extruded,printed,and sintered grits for use in precision grinding applications are critically reviewed.The paper concludes by explaining how such abrasives are used in practice by industrial manufacturers of high-precision products.
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