Temperature uniformity of profiled grinding wheel under high-frequency induction brazing

High-frequency induction brazing (HFIB) technology is one of the commonly used methods in brazing super abrasive grinding wheels. However, it’s difficult to obtain a uniform temperature distribution on the profiled wheel surface during HFIB, which is caused by the proximity and edge effects during high-frequency induction heating. In this study, the temperature uniformity of the profiled wheel surface and the optimization design of the coil were investigated by finite element simulation based on Box-Behnken design of response surface methodology. The mathematical model of average temperature and temperature uniformity was defined to evaluate the temperature distribution on the profiled surface of the grinding wheel. The regression equations of the response value average temperature and temperature uniformity were built based on the Box-Behnken design of simulation results. The two regression equations could well predict the results for the additional simulations. An optimization coil was designed for the brazing of profiled grinding wheel according to these regression equations. The experimental results showed good agreement with the simulation results within 4.62% errors, which verified the finite element model and the regression equations were all reliable. High-frequency induction brazing of profiled cBN grinding wheel showed that a consistent quality was obtained on the brazed wheel surface.