Tool life and workpiece surface integrity when turning an RR1000 nickel-based superalloy

The use of GH4169 nickel-based superalloy for the manufacture of gas turbine engines components for aerospace/energy applications has become a routine exercise. However, components with complex designs specifications might pose manufacturing challenges especially when grinding processes are needed to enable their compliance with tight industrial standards for workpiece surface integrity. Information on grinding processes for such sensitive industrial applications is scarce. The paper reports on the influence of grinding methods/strategies on the quality and integrity of workpiece surfaces obtained after abrasive belt grinding methods on GH4169 nickel-based superalloy. The influences of grinding speed, contact pressure and oscillation frequency on surface roughness were discussed. The performance of the abrasive belt and surface topography were discussed. As a result, the maximum surface roughness of Ra is 0.072μm, and have a good performance of the abrasive belt, it could be concluded that abrasive belt grinding might be considered as a viable process for grinding aero-engine components.

Download Full-text

High-feed turning of AISI D2 tool steel using multi-radii tool inserts: Tool life, material removed, and workpiece surface integrity evaluation

Materials and Manufacturing Processes ◽

10.1080/10426914.2016.1232815 ◽

2016 ◽

Vol 32 (6) ◽

pp. 670-677 ◽

Cited By ~ 13

Author(s):

Sarmad Ali Khan ◽

Muhammad Aftab Ahmad ◽

Muhammad Qaiser Saleem ◽

Zakria Ghulam ◽

Muhammad Asif Mahmood Qureshi

Keyword(s):

Tool Life ◽

Tool Steel ◽

Surface Integrity ◽

Workpiece Surface ◽

Aisi D2 ◽

High Feed ◽

Aisi D2 Tool Steel

Download Full-text

Experimental Study on Turning Nickel-Based Superalloy GH4033 with Coated Cemented Carbide Tools

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.191 ◽

2014 ◽

Vol 800-801 ◽

pp. 191-196

Author(s):

Bin Zhao ◽

Han Lian Liu ◽

Chuan Zhen Huang ◽

Bin Zou ◽

Hong Tao Zhu

Keyword(s):

Surface Roughness ◽

Tool Life ◽

Failure Modes ◽

Flank Wear ◽

Cutting Performance ◽

Cemented Carbide ◽

Nickel Based Superalloy ◽

Coated Tool ◽

Optimal Cutting Parameters ◽

Coated Cemented Carbide

The nickel-based superalloy GH4033 is one of the difficult-to-cut materials. In order to investigate the machinability of GH4033, the tool cutting performance, tool failure modes, tool life and the relationships between surface roughness and tool flank wear were studied by using different coated cemented carbide cutting tools under dry cutting. Aiming at the amount of metal removal combining with the tool life and surface quality, the better cutting tool coating type and optimal cutting parameters were obtained through the orthogonal experiments. The results showed that the cutting performance of TiCN coated tool (GC4235) was better than that of TiAlN coated tool (JC450V). With these two kinds of tools, the machined surface roughness decreased to a minimum value and then increased with the increase of flank wear. When cutting GH4033, the main wear mechanism for both of the two types of tools included adhesive wear, diffusive wear, abrasive wear, edge wear and coating peeling.

Download Full-text