Electrodischarge Methods of Shaping the Cutting Ability of Superhard Grinding Wheels

Gołąbczak, M.; Święcik, Robert; Gołąbczak, Andrzej; Kaczmarek, Dariusz; Dębkowski, Ryszard; Tomczyk, Barbara

doi:10.3390/ma14226773

Cited by 15 publications

(6 citation statements)

References 38 publications

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“…Machining is conducted with high-pressure coolant flow supplied into the grinding zone. This machining method is sometimes referred to as VIPER (very impressive performance extreme removal) [ 51 , 81 , 82 , 83 ].…”

Section: Methods Of Manufacturing Fir Tree Slots Of the Turbine Discsmentioning

confidence: 99%

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

2023

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This review article presents a summary of currently used and proposed methods of manufacturing fir tree slots of discs in turbine engines. The production of aircraft, including aircraft engines during times of overlapping global economic crises related to the COVID-19 pandemic or the war in Eastern Europe requires a quick response to the changing numbers of passengers and cargo. Similarly, the aviation industry must adapt to these conditions, and thus utilize flexible production methods allowing for a quick change in the design or type of a given part. Due to the constant adoption of new materials for the most critical aero engine parts and the necessity of complying with environmental regulations, it is necessary to search for new methods of manufacturing these parts, including fir tree slots. As an alternative to currently used expensive and energy-intensive broaching, many manufacturers try to implement creep feed grinding CFG or contour milling. However, other manufacturing methods, thus far rarely used for crucial machine parts such as WEDM, ECDM or AWJ, are gaining more and more popularity in the aviation industry. This article presents the advantages and shortcomings of these methods in the context of manufacturing fir tree slots.

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Section: Methods Of Manufacturing Fir Tree Slots Of the Turbine Discsmentioning

confidence: 99%

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

2023

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“…The studies undertaken by researchers are mainly focused on shaping the geometry, based on the use of unconventional machining technologies such as EDM [ 5 , 6 , 7 ], electrochemical machining [ 8 , 9 ], or hybrid machining [ 10 , 11 ]. An integral part of technology development is also the use of finishing treatments in the process of shaping a specific state of the surface layer [ 12 , 13 , 14 , 15 ]. The treatment under consideration in terms of surface finish is grinding.…”

Section: Introductionmentioning

confidence: 99%

Effects of a New Type of Grinding Wheel with Multi-Granular Abrasive Grains on Surface Topography Properties after Grinding of Inconel 625

et al. 2023

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Finishing operations are one of the most challenging tasks during a manufacturing process, and are responsible for achieving dimensional accuracy of the manufactured parts and the desired surface topography properties. One of the most advanced finishing technologies is grinding. However, typical grinding processes have limitations in the acquired surface topography properties, especially in finishing difficult to cut materials such as Inconel 625. To overcome this limitation, a new type of grinding wheel is proposed. The tool is made up of grains of different sizes, which results in less damage to the work surface and an enhancement in the manufacturing process. In this article, the results of an experimental study of the surface grinding process of Inconel 625 with single-granular and multi-granular wheels are presented. The influence of various input parameters on the roughness parameter (Sa) and surface topography was investigated. Statistical models of the grinding process were developed based on our research. Studies showed that with an increase in the cutting speed, the surface roughness values of the machined samples decreased (Sa = 0.9 μm for a Vc of 33 m/s for a multigranular wheel). Observation of the grinding process showed an unfavorable effect of a low grinding wheel speed on the machined surface. For both conventional and multigranular wheels, the highest value for the Sa parameter was obtained for Vc = 13 m/s. Regarding the surface topography, the observed surfaces did not show defects over large areas in the cases of both wheels. However, a smaller portion of single traces of active abrasive grains was observed in the case of the multi-granular wheel, indicating that this tool performs better finishing operations.

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“…In the place of discharge, a crater is formed. The complexity of the physical phenomena of the material removal process causes difficulties in identifying the influence of WEDM parameters on the effects of machining [32][33][34][35][36][37][38]. A significant part of the research has focused on the modeling of WEDM and its optimization [39][40][41][42][43][44].…”

Section: Introductionmentioning

confidence: 99%

Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy

Oniszczuk-Świercz

Świercz

2023

Materials

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The Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional finishing technology, such as machining, laser polishing, or mechanical polishing, is used to achieve desired surface properties. In this study, improving SLM Ti6Al4V alloy surface integrity using wire electrical discharge machining (WEDM) is proposed. The influence of finishing WEDM cuts and the discharge energy on the surface roughness parameters Sa, Svk, Spk, and Sk and the composition of the recast layer were investigated. The proposed finishing technology allows for significant improvement of the surface roughness by up to 88% (from Sa = 6.74 µm to Sa = 0.8 µm). Furthermore, the SEM analyses of surface morphology indicate improving surface integrity properties by removing the balling effect, unmelted particles, and the presence of microcracks. EDS analysis of the recast layer indicated a significant influence of discharge energy and the polarization of the electrode on its composition and thickness. Depending on the used discharge energy and the number of finishing cuts, changes in the composition of the material in the range of 2 to 10 µm were observed.

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Electrodischarge Methods of Shaping the Cutting Ability of Superhard Grinding Wheels

Cited by 15 publications

References 38 publications

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

Effects of a New Type of Grinding Wheel with Multi-Granular Abrasive Grains on Surface Topography Properties after Grinding of Inconel 625

Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy

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