Grinding temperature and power consumption in high speed grinding of Inconel 718 nickel-based superalloy with a vitrified CBN wheel

Dai, Chenwei; Ding, Wenfeng; Zhu, Yumei; Xu, Jie; Yu, Haiwu

doi:10.1016/j.precisioneng.2017.12.005

Cited by 126 publications

(23 citation statements)

References 49 publications

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“…Chen-Wei Dai et al [ 44 ] found white layer on the surface whilst grinding Inconel ® 718 under extreme conditions due to the quick jump from rapid heating to cooling. In this line, considering roughing strategies for flank SAM and flank milling as hard cutting conditions and suffering considerable thermal changes, it is important to point out that no white layer was found for any of these techniques.…”

Section: Resultsmentioning

confidence: 99%

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

González

Pereira

Fernández-Valdivielso

et al. 2018

Materials

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Thermoresistant superalloys present many challenges in terms of machinability, which leads to finding new alternatives to conventional manufacturing processes. In order to face this issue, super abrasive machining (SAM) is presented as a solution due to the fact that it combines the advantages of the use of grinding tools with milling feed rates. This technique is commonly used for finishing operations. Nevertheless, this work analyses the feasibility of this technique for roughing operations. In order to verify the adequacy of this new technique as an alternative to conventional process for roughing operations, five slots were performed in Inconel® 718 using flank SAM and flank milling. The results showed that flank SAM implies a suitable and controllable process to improve the manufacture of high added value components made by nickel-based superalloys in terms of roughness, microhardness, white layer, and residual stresses.

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Section: Resultsmentioning

confidence: 99%

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

González

Pereira

Fernández-Valdivielso

et al. 2018

Materials

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“…Meanwhile, the electroplated cubic boron nitride (CBN) wheel has obvious advantages in grain retention and shape retention and has been widely applied [5,6]. Ding et al [7] used brazed CBN wheel for creep feed grinding of nickel-based superalloy, the specific grinding energy of nickel-based superalloy is 200~300 J/mm 3 , and the grinding temperature is about 100 • C. Dai et al [8] carried out experiments on grinding Inconel 718 with the vitrified CBN wheels. The results show that under the given experimental conditions, the surface roughness R a can be less than 0.4 µm, and no distorted lattice or elongated grains are formed in the grinding surface/subsurface layer under the given experimental conditions.…”

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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“…Zhou et al [6] applied a finite element simulation model to investigate the high-speed grinding of the titanium matrix composites. Dai et al [7], Qian et al [8], and Gu et al [9] researched the temperature distribution and forces generated in the process of grinding various difficult-to-cut materials, such as Inconel 718, K4125, and DD6 nickel-based superalloys. Lei Zhang [10] focused on grind-hardening and the critical parameters of the austenitic and martensitic transformations of the surface layer.…”

Section: Introductionmentioning

confidence: 99%

“…Analysis of the temperature field and the stress-strain state of the workpiece requires studying heat transfer in the grinding zone and the impact that various grinding conditions have on the structure and residual stresses of a coating [7,[13][14][15]. Linking technological parameters with the most important criteria of the processed surface quality is an essential problem of mechanical engineering and CAD (computer-aided design) development.…”

Section: Introductionmentioning

confidence: 99%

Modelling of Temperature Field and Stress–Strain State of the Workpiece with Plasma Coatings during Surface Grinding

Usov

Tonkonogyi

Dašić³

et al. 2019

Machines

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Plasma coatings play a key role in surface tailoring through providing important advantages for tools during their further application. However, grinding these coatings may cause different defects such as grinding burns and cracks, structural changes to the coating material, and the destruction of adhesive contacts between the coating layer and the substrate. The reason for that is the high heat flux generated in the process of abrasive material removal due to the high friction and stresses. In order to define the optimal conditions for grinding plasma coatings, the mathematical model of the temperature thermal field and the stress–strain state during the grinding process is developed. Based on the temperature, strength, and fracture criteria, this mathematical model makes it possible to define the functional relationship between the technological characteristics of the grinding process and the conditions that provide the required quality of surface processing. The role of the structural defects that are generated while coatings are being sprayed, as well as during coating adhesion, is also considered. An algorithm developed to present the results of the modelling process enables checking if the input parameters meet the condition of zero-defect grinding of a workpiece, and determining an expected surface roughness. Input parameters include the grinding wheel geometry, its abrasive properties, the wheel speed, longitudinal and transverse motion, grinding depth, and the use of the cutting fluid. Experimental testing of this study shows the way in which the regime of the grinding process and different grinding wheel parameters influence the physical and mechanical properties of the surface layer.

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Grinding temperature and power consumption in high speed grinding of Inconel 718 nickel-based superalloy with a vitrified CBN wheel

Cited by 126 publications

References 49 publications

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces

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

Modelling of Temperature Field and Stress–Strain State of the Workpiece with Plasma Coatings during Surface Grinding

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