scholarly journals Study of Manufacturing Process of Holes in Aeroengine Heat Shield

2019 ◽  
Vol 2019 ◽  
pp. 1-11
Author(s):  
Anyuan Jiao ◽  
Weijun Liu
Keyword(s):  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Aircraft Engine ◽  
Heat Shield ◽  
Drilling Process ◽  
High Plasticity ◽  
Processing Efficiency ◽  
Technical Parameters ◽  
Nickel Based Superalloy ◽  
Heat Shields

The nickel-based superalloy GH3128 with high plasticity, high long-lasting creep strength, good resistance to oxidation and stamping, and good welding performance is widely used in aircraft engine heat shields. The many holes that need to be machined on the heat shield are not only small in diameter but also dense, and GH3128 as a typical hard-to-process material has the problems of large cutting force, high cutting temperature, and serious hardening. Therefore, poor dimensional accuracy and residual burrs have become the main factors that limit the processing efficiency and processing quality. So, a novel combination of manufacturing processes was proposed. Firstly, laser cutting technology was used to process the base hole in a GH3128 plate, followed by reaming, and finally, using a magnetic abrasive finishing effector to remove burrs formed during the first two steps. The whole drilling process of the heat shields fully meets the requirements of the technical parameters. This study provides new reference for manufacturing the holes of a heat shield and other similar porous parts.

Investigation of Heat Pipe Cooling in Drilling Applications: Part 2—Thermal, Structural Static, and Dynamic Analyses

2009 ◽  
Author(s):  
Lin Zhu ◽  
Tien-Chien Jen ◽  
Chen-Long Yin ◽  
Yi-Hsin Yen ◽  
Mei Zhu ◽  
...  
Keyword(s):  
Heat Pipe ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Mechanical Effect ◽  
Machining Process ◽  
Drilling Process ◽  
Dynamic Analyses ◽  
Thermal Wear ◽  
3D Finite Element Method

Drilling is a highly complex machining process coupled with thermo-mechanical effect. Both the rapid plastic deformation of the workpiece and the friction along the drill-chip interface can contribute to localized heating and increasing temperature in the workpiece and tool. The cutting temperature at the tool-chip interface plays an important role in determining the tool thermal wear. This in turn affects the dimensional accuracy of the workpiece and the tool life of drill. A new embedded heat pipe technology has been proven to be able to effectively not only remove the heat generated at the tool-chip interface in drilling, but also minimize pollution and contamination of the environment caused by cutting fluids. Less tool wear can then be achieved, thus prolonging the tool life. 3D Finite Element method using COSMOS/works is employed to study coupled effects of thermal, structural static and dynamic analyses in a drilling process to check the feasibility and effectiveness of the heat pipe drill. Four different cases, solid drill without coolant, solid drill with coolant, heat pipe drill, and heat pipe drill with coolant, are explored, respectively. The results from this study can be used to define geometric parameters for optimal designs.

Research Status of Subsequent Machining of Laser Cladding Layers

2020 ◽  
Vol 15 ◽  
Author(s):  
Lei Li ◽  
Yujun Cai ◽  
Guohe Li ◽  
Meng Liu
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Laser Cladding ◽  
Wear Surface ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Cladding Layer ◽  
Cladding Layers

Background: As an important method of remanufacturing, laser cladding can be used to obtain the parts with specific shapes by stacking materials layer by layer. The formation mechanism of laser cladding determines the “Staircase effect”, which makes the surface quality can hardly meet the dimensional accuracy of the parts. Therefore, the subsequent machining must be performed to improve the dimensional accuracy and surface quality of cladding parts. Methods: In this paper, chip formation, cutting force, cutting temperature, tool wear, surface quality, and optimization of cutting parameters in the subsequent cutting of laser cladding layer are analyzed. Scholars have expounded and studied these five aspects but the cutting mechanism of laser cladding need further research. Results: The characteristics of cladding layer are similar to that of difficult to machine materials, and the change of parameters has a significant impact on the cutting performance. Conclusion: The research status of subsequent machining of cladding layers is summarized, mainly from the aspects of chip formation, cutting force, cutting temperature, tool wear, surface quality, and cutting parameters optimization. Besides, the existing problems and further developments of subsequent machining of cladding layers are pointed out. The efforts are helpful to promote the development and application of laser cladding remanufacturing technology.

scholarly journals Repair of Precision Castings Made of the Inconel 713C Alloy

2017 ◽  
Vol 17 (3) ◽  
pp. 210-216
Author(s):  
K. Łyczkowska ◽  
J. Adamiec
Keyword(s):  
Model Test ◽  
Aircraft Engine ◽  
Casting Defects ◽  
Exhaust Gas ◽  
Plasma Arc ◽  
Nickel Based Superalloy ◽  
Melted Zone ◽  
Base Materials ◽  
Inconel 713C ◽  
Engine Components

Abstract Inconel 713C precision castings are used as aircraft engine components exposed to high temperatures and the aggressive exhaust gas environment. Industrial experience has shown that precision-cast components of such complexity contain casting defects like microshrinkage, porosity, and cracks. This necessitates the development of repair technologies for castings of this type. This paper presents the results of metallographic examinations of melted areas and clad welds on the Inconel 713C nickel-based superalloy, made by TIG, plasma arc, and laser. The cladding process was carried out on model test plates in order to determine the technological and material-related problems connected with the weldability of Inconel 713C. The studies included analyses of the macro- and microstructure of the clad welds, the base materials, and the heat-affected zones. The results of the structural analyses of the clad welds indicate that Inconel 713C should be classified as a low-weldability material. In the clad welds made by laser, cracks were identified mainly in the heat-affected zone and at the melted zone interface, crystals were formed on partially-melted grains. Cracks of this type were not identified in the clad welds made using the plasma-arc method. It has been concluded that due to the possibility of manual cladding and the absence of welding imperfections, the technology having the greatest potential for application is plasma-arc cladding.

Uncertainty Quantification of Thermocouple Air Temperature Measurement in Highly Radiative Environment: Application to Turbofan Engine Compartment

2016 ◽  
Author(s):  
Y. Sommerer ◽  
V. Drouin ◽  
X. Nicolas ◽  
B. Trouette
Keyword(s):  
Heat Flux ◽  
Temperature Measurement ◽  
Air Temperature ◽  
Data Bank ◽  
Heat Shield ◽  
Engine Compartment ◽  
Heat Shields ◽  
Air Speed ◽  
Thermocouple Temperature ◽  
The Impact

This paper focuses on thermocouple air temperature measurement uncertainty due to the radiative fluxes present in the engine compartment where engine case skin temperature can exceed 900 K. To really measure air temperature, the convective heat flux in the thermocouple bead must be predominant. This is why heat shields are used in order to reduce the radiative heat flux on the bead. However, in engine compartment, the heat shield orientation must be optimized since numerous hot walls surround the thermocouple. In order to evaluate the impact of badly oriented heat shields and to provide a data bank for numerical simulation validations, a heated wind tunnel has been used. It has been shown that the uncertainty on the thermocouple temperature can reach dozens of degrees depending on the air speed and the heat shield orientation. Furthermore a specific 3D thermocouple model has been build and validated by comparison with the lab measurements. Then this thermocouple 3D model has been integrated in the whole engine compartment aero-thermal model in order to quantify the uncertainty of the thermocouple air temperature measurement in the real engine environment.

Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

2012 ◽  
Vol 497 ◽  
pp. 94-98
Author(s):  
Yang Qiao ◽  
Xiu Li Fu ◽  
Xue Feng Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Failure Mechanisms ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

scholarly journals Study on the Effect of Powder-Bed Fusion Process Parameters on the Quality of as-Built IN718 Parts Using Response Surface Methodology

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1180
Author(s):  
Bharath Bhushan Ravichander ◽  
Amirhesam Amerinatanzi ◽  
Narges Shayesteh Moghaddam
Keyword(s):  
Process Parameters ◽  
Oil And Gas ◽  
Dimensional Accuracy ◽  
Powder Bed ◽  
Nickel Based Superalloy ◽  
Optimal Processing ◽  
Contour Plots ◽  
In718 Superalloy ◽  
Scan Speed ◽  
Density Values

Inconel 718 (IN718) is a nickel-based superalloy which is widely used in aerospace, oil, and gas industries due to its outstanding mechanical properties at high temperatures, corrosion, fatigue resistance, and excellent weldability. Selective laser melting (SLM), one of the most used powder-bed based methods, is being extensively used to fabricate functional IN718 components with high accuracy. The accuracy and the properties of the SLM fabricated IN718 parts highly depend on the process parameters employed during fabrication. Thus, depending on the desired properties, the process parameters for a given material need to be optimized for improving the overall reliability of the SLM devices. In this study, design of experiment (DOE) was used to evaluate the dimensional accuracy, composition, and hardness corresponding to the interaction between the SLM process parameters such as laser power (P), scan speed (v), and hatch spacing (h). Contour plots were generated by co-relating the determined values for each characteristic and the process parameters to improve the as-built characteristics of the fabricated IN718 parts and reduce the post-processing time. The outcome of this study shows a range of energy density values for the IN718 superalloy needed to attain optimal values for each of the analyzed characteristics. Finally, an optimal processing region for SLM IN718 fabrication was identified which is in accordance with the values for each characteristic mentioned in literature.

scholarly journals On the influence of thermal processes on the dynamics of a drill during deep hole machining

2019 ◽  
Vol 298 ◽  
pp. 00008
Author(s):  
Leonid Kondratenko ◽  
Lubov Mironova
Keyword(s):  
Heat Source ◽  
Dimensional Accuracy ◽  
Thermal Processes ◽  
Drilling Process ◽  
Drill Bit ◽  
Dynamic Features ◽  
Deep Drilling ◽  
Gun Drill ◽  
Heat Sinking ◽  
Hole Machining

Deep drilling process has been studied and dynamic features of interaction the cutting part of the gun drill with the detail have been identified. Thermal processes of cutting and heat sinking in the interacting chains were analyzed: “heat source – workpiece”; “heat source - chips”; heat source – tool”; “heat source – cooling liquid”. It has been noted that the vibrations lead to the loss of dimensional accuracy of the part fabrication as well as hole surface quality. Mathematical dependence of the longitudinal and torsional oscillations of the cutting drill bit is determined and the influence of heat flow pulsations on the friction coefficients and cutting force is revealed.

Processing Stability Analysis of Wire Cut Electric Discharge Machine with High Speed

2013 ◽  
Vol 443 ◽  
pp. 74-78
Author(s):  
Jing Wang ◽  
Ming Gui Zhou
Keyword(s):  
Electric Discharge ◽  
High Speed ◽  
Dimensional Accuracy ◽  
Processing Parameters ◽  
Cutting Fluid ◽  
Processing Efficiency ◽  
Electric Discharge Machine ◽  
Wire Cutting ◽  
Discharge Machine ◽  
Processing Stability

In this article, unstable factor analysis is done in Wire cut electric discharge machine with high speed (WEDM HS), which focus on effect of processing Stability from electrical processing parameters, machine parameters, electrode wire, cutting fluid and conductive block, and how to adjust and excluding factors in order to enhance WEDM processing stability ,ensure machine parts surface quality, dimensional accuracy and processing efficiency.

Morphology of γ' Precipitates in Second Stage High Pressure Turbine Blade of Single Crystal Nickel-Based Superalloy after Serviced

2010 ◽  
Vol 638-642 ◽  
pp. 2291-2296 ◽  
Author(s):  
N. Miura ◽  
K. Nakata ◽  
M. Miyazaki ◽  
Y. Hayashi ◽  
Y. Kondo
Keyword(s):  
High Pressure ◽  
Single Crystal ◽  
Turbine Blade ◽  
Leading Edge ◽  
Aircraft Engine ◽  
Pressure Side ◽  
High Pressure Turbine ◽  
Second Stage ◽  
Nickel Based Superalloy ◽  
The Matrix

The morphology of the ’ precipitates in the single crystal nickel-based superalloy serviced as the second stage high pressure turbine blade of the aircraft engine was examined. The aim of this work was to estimate the temperature and the stress distribution, and the stress direction of the blade in service. The blade was cut into three parts parallel to (001) plane at 8, 40 and 64mm from the tip. These parts were named as the tip, middle and root parts. Furthermore, these three parts were cut into six parts parallel to {100} which were almost normal to the surface from the leading to the trailing edge at interval of 6mm. Microstructure observations by a FE-SEM were carried out on the thirty portions of each part parallel to (001) and {100} planes at the vicinity of the interface between the coating layer and the matrix in the suction and pressure sides. Most of the ’ precipitates contacted each other toward almost parallel to the surface at the vicinity of the interface in the blade. Especially, at the leading edge of the pressure side of the tip and middle parts, the rafted /’ structures start to collapse. Consequently, the blade in service, at the leading edge of the pressure side of the tip and middle parts were exposed to the highest temperature and stress conditions. And the multi-axial compressive stresses parallel to the blade surface were expected to act on the blade in service.

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