Temperature modeling of creep-feed grinding processes for nickel-based superalloys with variable heat flux distribution

Grimmert, Adina; Pachnek, Florian; Wiederkehr, Petra

doi:10.1016/j.cirpj.2023.01.011

“…Grinding is widely used in the machining of many key parts in the aero-engine, such as disk, shaft, blade and case [4,5]. However, large grinding force, severe tool wear, easy ground surface burnout and low material removal rate commonly occur in the conventional grinding (CG) of K4002 nickel-based superalloy due to the ideal material properties [6][7][8], which brings challenges for the high efficiency grinding technology.…”

Section: Introductionmentioning

confidence: 99%

Effect of intermittent cutting behavior on grinding force in ultrasonic vibration-assisted grinding of K4002 nickel-based superalloy

Cao,

Zhao,

Ding

et al. 2024

Preprint

0

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The intermittent cutting behavior, performing as periodic contact phase and separation phase between abrasive grit and workpiece, is an important characteristic in the ultrasonic vibration-assisted grinding (UVAG). This study investigated the effect of intermittent cutting behavior on the grinding force in UVAG. At first, a grinding force model was established by determining the quantity of effective grits and the grinding force of a single grit. Then the influences of ultrasonic vibration phase on the intermittent cutting behavior and grinding force were discussed. Finally, the prediction accuracy of the model was tested through experiments. Results indicated that the quantity of effective grits, unchanged chip thickness and proportion of grits at the sliding, plowing, cutting stages were all changed with the vibration phase. A large unchanged chip thickness and 56% effective grits at the cutting stage were generated at the start of the grits-wheel contact phase. Then, the quantity of effective grits firstly increased to maximum 232 at the vibration phase of 0.5π and then decreased to zero when entering the grits-wheel separation phase. The maximum error of the grinding force model was 15%, indicating that the model was of high accuracy for the force prediction in UVAG.

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“…Occasionally, inverse heat transfer techniques are employed to deduce the temperature and heat flow on the sliding surface using data obtained from these conventional thermocouples (for instance, [ 25 ]). For grinding operations, embedded thermocouples are an interesting alternative in creep-feed grinding [ 26 ], in which temperature gradients are considerably smaller than those in conventional grinding. Still, the problems related to sensor location with respect to the ground surface (which is continuously being removed), and the distortion of the temperature field produced by the machined hole, persist.…”

Section: Introductionmentioning

confidence: 99%

Accurate Measurement of Temperatures in Industrial Grinding Operations with Steep Gradients

Pombo,

Sánchez,

Martin

et al. 2024

Sensors

0

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Due to the continuously growing demands from high-added-value sectors such as aerospace, e-mobility or biomedical bound-abrasive technologies are the key to achieving extreme requirements. During grinding, energy is rapidly dissipated as heat, generating thermal fields on the ground part which are characterized by high temperatures and very steep gradients. The consequences on the ground part are broadly known as grinding burn. Therefore, the measurement of workpiece temperature during grinding has become a critical issue. Many techniques have been used for temperature measurement in grinding, amongst which, the so-called grindable thermocouples exhibit great potential and have been successfully used in creep-feed grinding operations, in which table speed is low, and therefore, temperature gradients are not very steep. However, in conventional grinding operations with faster table speeds, as most industrial operations are, the delay in the response of the thermocouple results in large errors in the maximum measured value. In this paper, the need for accurate calibration of the response of grindable thermocouples is studied as a prior step for signal integration to correct thermal inertia. The results show that, if the raw signal is directly used from the thermocouples, the deviation in the maximum temperature with respect to the theoretical model is over 200 K. After integration using the calibration constants obtained for the ground junction, the error can be reduced to 93 K even for feed speeds as high as 40 m/min and below 20 K for lower feed speeds. The main conclusion is that, following the proposed procedure, maximum grinding temperatures can be effectively measured using grindable thermocouples even at high values of table speed.

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“…Grinding is widely used in the machining of many key parts in the aero-engine, such as disk, shaft, blade and case [4,5]. However, large grinding force, severe tool wear, easy ground surface burnout and low material removal rate commonly occur in the conventional grinding (CG) of K4002 nickel-based superalloy due to the ideal material properties [6][7][8], which brings challenges for the high efficiency grinding technology.…”

Section: Introductionmentioning

confidence: 99%

Intermittent cutting behavior and grinding force model in ultrasonic vibration-assisted grinding K4002 nickel-based superalloy

Cao,

Zhao,

Ding

et al. 2024

Int J Adv Manuf Technol

2

0

View full text Add to dashboard Cite

The intermittent cutting behavior, performing as periodic contact phase and separation phase between abrasive grit and workpiece, is an important characteristic in the ultrasonic vibration-assisted grinding (UVAG). This study investigated the effect of intermittent cutting behavior on the grinding force in UVAG. At first, a grinding force model was established by determining the quantity of effective grits and the grinding force of a single grit. Then the influences of ultrasonic vibration phase on the intermittent cutting behavior and grinding force were discussed. Finally, the prediction accuracy of the model was tested through experiments. Results indicated that the quantity of effective grits, unchanged chip thickness and proportion of grits at the sliding, plowing, cutting stages were all changed with the vibration phase. A large unchanged chip thickness and 56% effective grits at the cutting stage were generated at the start of the grits-wheel contact phase. Then, the quantity of effective grits firstly increased to maximum 232 at the vibration phase of 0.5π and then decreased to zero when entering the grits-wheel separation phase. The maximum error of the grinding force model was 15%, indicating that the model was of high accuracy for the force prediction in UVAG.

show abstract

Temperature modeling of creep-feed grinding processes for nickel-based superalloys with variable heat flux distribution

Cited by 11 publications

References 37 publications

Effect of intermittent cutting behavior on grinding force in ultrasonic vibration-assisted grinding of K4002 nickel-based superalloy

Effect of intermittent cutting behavior on grinding force in ultrasonic vibration-assisted grinding of K4002 nickel-based superalloy

Accurate Measurement of Temperatures in Industrial Grinding Operations with Steep Gradients

Intermittent cutting behavior and grinding force model in ultrasonic vibration-assisted grinding K4002 nickel-based superalloy

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