Comparison on grindability and surface integrity in creep feed grinding of GH4169, K403, DZ408 and DD6 nickel-based superalloys

Miao, Qing; Ding, Wenfeng; Kuang, Weijie; Yang, Chuanfang

doi:10.1016/j.jmapro.2019.11.027

Cited by 71 publications

(17 citation statements)

References 43 publications

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“…Nickel superalloys are widely used in the aeronautical engineering eld due to their high thermal stability, fatigue resistance, high-temperature strength, and corrosion resistance. Nickel superalloys are applied in aero-engine components such as turbine discs, turbine blades, and the engine cabins of aero-engines [1][2][3]. However, due to their high strengths at elevated temperatures, high work hardening, and low thermal diffusivity, nickel-based superalloys are categorized as di cult-to-machine materials [4].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the wear behavior of abrasive grits in a dry machining Inconel 718 narrow-deep-groove with a single-layer cubic boron nitride grinding wheel

Liang

Shen

et al. 2021

Int J Adv Manuf Technol

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The wear behavior of a single-layer electroplated cubic boron nitride (cBN) grinding wheel was investigated in creep feed pro le grinding Inconel 718 narrow-deep-groove with a width of 2 mm. In this paper, the protrusion height of cBN grits on the side edge of the grinding wheel was measured by threedimensional optical pro ler, and a scanning electron microscope was used to detect the topography of worn cBN grit and the nickel bonding layer. The investigation results indicated that the steady wear stage of the grinding wheel shared more than 84.6% of the wheel lifespan, and the machining precision of the grinding wheel was kept at a high level. The fracture mode of the cBN grit was proven to be cleavage. The source of the cleavage cracks was observed on the surface of wear at or the side surface of the cBN grit.The holding strength of cBN grit could be weakened due to the joint surface breakage, the displacement of grit, or the cracks of the nickel bonding layer. The transition layer was contributed to the decrease of the bonding strength. Severe macro fractures and the concentration of pulled out grits were observed on the transition edge and the inner area of the side edge, separately. This study provides a deep understanding of the wear mechanism of a single-layer electroplated cBN grinding wheel.

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Section: Introductionmentioning

confidence: 99%

Investigation of the wear behavior of abrasive grits in a dry machining Inconel 718 narrow-deep-groove with a single-layer cubic boron nitride grinding wheel

Liang

Shen

et al. 2021

Int J Adv Manuf Technol

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“…There are many studies on the surface quality and wear of grinding tool in the grinding process. Miao et al [5] conducted a comparative study on the grindability of superalloy GH4169, K403, directionally solidified superalloy DZ408 and single crystal superalloy DD6 during the creep-feeding grinding process, and analyzed the grinding force, grinding ratio, wear of wheel and surface integrity. Ruzzi et al [6] analyzed the influence of the several grinding parameters on surface integrity of nickel-based superalloy Inconel 625.…”

Section: Introductionmentioning

confidence: 99%

Study on theoretical model of roughness and wear of the microgrinding tool in microgrinding nickel-based single crystal superalloy

Zhou

Wen

Yin

et al. 2021

J Braz. Soc. Mech. Sci. Eng.

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Nickel-based single crystal superalloy has no grain boundary and excellent high-temperature performance. The traditional grinding mechanism of shearing and slipping along the polycrystalline material's grain boundary based on the theory of elastic-plastic deformation is not suitable for grinding single crystal parts. At present, there are few studies on microgrinding nickel-based single crystal superalloy. The grinding quality directly affects the workpiece's service life. To realize highquality and low-damage grinding nickel-based single crystal superalloy (001) crystal plane, this paper studied the surface roughness and the wear of the microgrinding tool. Firstly, it was assumed that the protrusion height of the electroplated abrasives on the grinding tool obeyed Rayleigh distribution. Based on the cutting state of abrasives, the prediction model of surface roughness of microgrinding nickel-based single crystal superalloy was established and verified by experiments. Secondly, the effect of grinding parameters on microgrinding surface roughness was analyzed through a single-factor experiment. Finally, the main wear forms, wear mechanism of grinding tool and the influence of grinding parameters on wear of grinding tool were analyzed. The results showed: although there was some error between the predicted value and the experimental value, the predicted value of the roughness and the experimental value had the same trend with the change of microgrinding parameters; with the increase in spindle speed (n g ) and the decrease in grinding depth (a p ), the surface roughness of microgrinding nickel-based single crystal superalloy showed a decreasing trend; with the increase in feeding rate (v w ), the surface roughness increased obviously; the wear of the grinding tool could be divided into five forms; the diameter of the microgrinding tool showed a trend of rapid reduction, then steady reduction, and finally rapid reduction under all grinding parameters. This study provided an important theoretical and practical reference for the manufacturing of nickel-based single crystal superalloy microparts.

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“…As a typical nickel-based superalloy [1], power metallurgy superalloy FGH96 has excellent high-temperature resistance and anti-fatigue performance. However, nickel-based superalloy has the characteristics of low thermal conductivity, high chemical affinity toward tool materials, and surface integrity problems [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

Influence of Electroplated CBN Wheel Wear on Grinding Surface Morphology of Powder Metallurgy Superalloy FGH96

Wang

et al. 2020

Materials

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The electroplated cubic boron nitride (CBN) wheel has perfect precision retention and high-temperature grinding performance, which is widely used in the field of grinding difficult-to-cut materials, such as nickel-based superalloy. However, the research on the influence law and mechanism of grinding surface morphology affected by the wear state of small-size grinding wheel is insufficient, which limits the further promotion and application of electroplated CBN wheel in the field of precision grinding of superalloy materials. Based on the in-depth analysis of the structure of FGH96 turbine disk, and combined with the actual processing requirements, the electroplated CBN wheel was designed, and the abrasive grains size selection experiments and CBN wheel wear experiments were then carried out for the powder metallurgy superalloy FGH96 in turn. The influence law of the abrasive grain size of CBN grinding wheel and the wear state of grinding wheel on the surface morphology was investigated, respectively. The obtained results showed that under the given processing parameters, the surface roughness Ra using 400# and 600# electroplated CBN wheels are around 0.66 μm and 0.53 μm during the normal wear state of grinding wheels, respectively, which can meet the requirement of surface quality less than Ra 0.8 μm in engineering application of turbine disk, and prove the feasibility of small-size CBN wheel grinding FGH96. In addition, the failure form of electroplated CBN wheel is mainly the accumulation and adhesion of abrasive debris, and the crushing and shedding of abrasive grain are hard to appear.

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Comparison on grindability and surface integrity in creep feed grinding of GH4169, K403, DZ408 and DD6 nickel-based superalloys

Cited by 71 publications

References 43 publications

Investigation of the wear behavior of abrasive grits in a dry machining Inconel 718 narrow-deep-groove with a single-layer cubic boron nitride grinding wheel

Investigation of the wear behavior of abrasive grits in a dry machining Inconel 718 narrow-deep-groove with a single-layer cubic boron nitride grinding wheel

Study on theoretical model of roughness and wear of the microgrinding tool in microgrinding nickel-based single crystal superalloy

Influence of Electroplated CBN Wheel Wear on Grinding Surface Morphology of Powder Metallurgy Superalloy FGH96

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