Surface roughness and fracture cracks of Al2O3/TiO2 composite coating by wet chemical mechanical grinding with structured abrasives pad

Abstract

In the fields of wind power, and other industries, the Al2O3/TiO2 coating is prepared and ground on the bearing ring, in order to obtain the insulation resisting the electrical erosion for the motors at high voltage. A novel wet chemical mechanical grinding (WCMG) method is proposed to finish this hard-brittle composite material, utilizing the structured diamond abrasives pad and the NaOH solution. The softened workpiece's surface under the chemical reaction was demonstrated by means of Raman spectrum, indentation and scratching tests. The analytical model of surface roughness and fracture cracks is established based on the synthesis of geometry and kinematics, contact mechanics, material removal and indentation fracture mechanics. The surface roughness of coating was reduced from initial Sa 3.293 μm down to final Sa 0.049 μm in the WCMG process with grain size 3 μm and pH 12.01, mostly attributed to the ductile removal of chemically softened coating surface.

Keywords

• Hard-brittle composite
• Chemical mechanical grinding
• Ductile removal
• Surface integrity
• Indentation fracture mechanics