High Speed Grinding of Nickel-Based Superalloy with Single Diamond Grit

2011 ◽  
Vol 325 ◽  
pp. 140-146 ◽  
Author(s):  
Z.Z. Chen ◽  
Jiu Hua Xu ◽  
W.F. Ding ◽  
Z. Cheng ◽  
Y.C. Fu
Keyword(s):  
High Speed ◽  
Chip Thickness ◽  
Diamond Grit ◽  
Nickel Based Superalloy ◽  
Grinding Speed ◽  
High Speed Grinding ◽  
Grinding Mechanism ◽  
Set Up ◽  
Serrated Chips ◽  
Single Grit Grinding

Nickel-based superalloy plays an extremely important role in gas turbine engines in aerospace industry. To understand the high and super high speed grinding mechanism of nickel-based superalloy, the single-grit grinding mechanism is needed to be investigated. Previous studies on single grit were all carried out by mean of cutting or scratching. In this work, a novel experimental set-up of single-grit grinding had been developed to meet the reality of the complex kinematic grinding process. Grooves and collected chips were investigated in grinding of a typical nickel-based alloy GH4169 with wheel speed up to 150 m/s. The groove integrity is improved by increasing the grinding speed even though the chip thickness is kept constant. The typical serrated chips were observed and the frequency of chip segmentation increases linearly with the increasing of the grinding speed. Under high and super high grinding, the thermal softening due to the high temperature in adiabatic shear zone contributes to accelerate the chip formation and leads to decrease the grinding force.

Forces and Chip Morphology of Nickel-Based Superalloy Inconel 718 during High Speed Grinding with Single Grain

2013 ◽  
Vol 589-590 ◽  
pp. 209-214 ◽  
Author(s):  
Jia Yan Zhao ◽  
Yu Can Fu ◽  
Jiu Hua Xu ◽  
Lin Tian ◽  
Lu Yang
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Groove Surface ◽  
Nickel Based Superalloy ◽  
High Speed Grinding ◽  
Grinding Mechanism ◽  
Single Grain ◽  
Diamond Grain

Single-grain grinding test plays an important part in studying the high speed grinding mechanism of materials. In this paper, a new experimental system for high speed grinding test with single diamond grain is presented. The differences of surface topography and chip morphology of Inconel 718 machined by single diamond grain and single CBN grain were evaluated. The grinding forces and corresponding maximum undeformed chip thickness were measured under different grinding speeds. The chips, characterized by crack and segment band feature like the cutting segmented chips, were collected to study the high speed grinding mechanism of nickel-based superalloy. The results show that the grinding speed has an important effect on the forces and chip formation, partly due to the temperature variation. As the speed increases, the groove surface becomes smoother.

Removal Mechanism of Titanium Alloy Ti6Al4V Based on Single-Grain High Speed Grinding Test

2011 ◽  
Vol 487 ◽  
pp. 39-43 ◽  
Author(s):  
L. Tian ◽  
Yu Can Fu ◽  
W.F. Ding ◽  
Jiu Hua Xu ◽  
H.H. Su
Keyword(s):  
Titanium Alloy ◽  
High Speed ◽  
Chip Thickness ◽  
Wheel Speed ◽  
High Speed Grinding ◽  
Tc4 Alloy ◽  
Grinding Mechanism ◽  
Single Grain ◽  
On Chip ◽  
Titanium Alloy Ti6al4v

Single-grain grinding test plays an important part in studying the high speed grinding mechanism of materials. In this paper, a new method and experiment system for high speed grinding test with single CBN grain are presented. In order to study the high speed grinding mechanism of TC4 alloy, the chips and grooves were obtained under different wheel speed and corresponding maximum undeformed chip thickness. Results showed that the effects of wheel speed and chip thickness on chip formation become obvious. The chips were characterized by crack and segment band feature like the cutting segmented chips of titanium alloy Ti6Al4V.

Study on the Simulation Model and Characteristics of High-Speed Grinding for Ceramics

2011 ◽  
Vol 138-139 ◽  
pp. 662-667 ◽  
Author(s):  
Yi Chu Yuan ◽  
Bei Zhi Li ◽  
Zhen Xin Zhou ◽  
Qiang Zhang
Keyword(s):  
Simulation Model ◽  
High Speed ◽  
Simulation Experiment ◽  
Surface Damage ◽  
Material Behavior ◽  
Engineering Ceramic ◽  
Ceramic Machining ◽  
High Speed Grinding ◽  
Grinding Mechanism ◽  
Single Grit Grinding

Engineering ceramic machining would bring out several kinds of surface damage owing to its hard and brittle nature. In this paper, a simulation model of single-grit grinding for silicon carbide (Sic) was established to explore the high-speed grinding mechanism. The material behavior was described with the Johnson-Holmquist Ⅱ (JH-2) model. According to the simulation experiment results, the optimal grinding parameters to achieve ductile grinding for Sic has been analyzed, which would provide theoretical basis and take surface damage under control.

Chip formation of nickel-based superalloy in high speed grinding with single diamond grit

2012 ◽  
Vol 5 (2) ◽  
pp. 93 ◽  
Author(s):  
Zhenzhen Chen ◽  
Lin Tian ◽  
Yucan Fu ◽  
Jiuhua Xu ◽  
Wenfeng Ding ◽  
...  
Keyword(s):  
Chip Formation ◽  
High Speed ◽  
Diamond Grit ◽  
Nickel Based Superalloy ◽  
High Speed Grinding

Temperature Simulation in High-Speed Grinding by Using Deform-3D

2011 ◽  
Vol 189-193 ◽  
pp. 1849-1853 ◽  
Author(s):  
Jing Zhu Pang ◽  
Bei Zhi Li ◽  
Jian Guo Yang ◽  
Zhen Xin Zhou
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Element Model ◽  
Element Analysis ◽  
Strain And Strain Rate ◽  
High Speed Grinding ◽  
Grinding Mechanism ◽  
Temperature Strain ◽  
Grinding Simulation ◽  
Deform 3D

Grinding is one of the most important operations in material processing. The study on grinding mechanism is difficult to carry out because of the difficulty in measuring the actual grinding temperature, stress and strain by experiments. Finite element analysis software Deform-3D is employed to create the Johnson-Cook material constitutive model for high-speed grinding simulation. Grinding model was constructed to reflect the temperature, strain and strain rate in the process of grinding 40Cr steel. The temperature of grinding area in simulation is analyzed to verify whether the finite element model is reasonable.

Theoretical Analysis of Serrated Chip Formation Based on Ideal Models in High Speed Cutting

2010 ◽  
Vol 154-155 ◽  
pp. 239-245
Author(s):  
Chong Yang Gao ◽  
Bin Fang ◽  
Yuan Tong Gu
Keyword(s):  
Chip Formation ◽  
High Speed ◽  
Engineering Application ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Formation Model ◽  
Serrated Chip ◽  
Serrated Chip Formation ◽  
Serrated Chips ◽  
The Ideal

In this paper, two ideal formation models of serrated chips, the symmetric formation model and the unilateral right-angle formation model, have been established for the first time. Based on the ideal models and related adiabatic shear theory of serrated chip formation, the theoretical relationship among average tooth pitch, average tooth height and chip thickness are obtained. Further, the theoretical relation of the passivation coefficient of chip’s sawtooth and the chip thickness compression ratio is deduced as well. The comparison between these theoretical prediction curves and experimental data shows good agreement, which well validates the robustness of the ideal chip formation models and the correctness of the theoretical deducing analysis. The proposed ideal models may have provided a simple but effective theoretical basis for succeeding research on serrated chip morphology. Finally, the influences of most principal cutting factors on serrated chip formation are discussed on the basis of a series of finite element simulation results for practical advices of controlling serrated chips in engineering application.

New Development of Supersonic Surface Grinding Machine Tool with a Linear-Motor-Driven Table System

2016 ◽  
Vol 1136 ◽  
pp. 667-672
Author(s):  
Lu Yang ◽  
Yu Can Fu ◽  
Jiu Hua Xu ◽  
Yong Tao Liu
Keyword(s):  
Machine Tool ◽  
High Speed ◽  
High Performance ◽  
Linear Motor ◽  
Grinding Wheel ◽  
Research Activities ◽  
High Speed Grinding ◽  
Grinding Mechanism ◽  
Speed Up ◽  
Grinding Machine

Ultra-high speed grinding (UHSG) is a significant and promising machining technology in grinding hard-to-cut materials. To find out the aerodynamics of the grinding wheel body when the airflow field has subsonic, transonic, and supersonic speed characteristics and clarify the corresponding influence on the grinding mechanism, the study is conducted to develop a supersonic grinding machine tool that is capable of being operated at extreme wheel speed up to 450 m/s and meanwhile accompanying with high grinding capability. In accordance with the main design objectives, a high performance grinding motorized spindle with maximum rotational speed 36000r/min and maximum power 28kW is developed. The linear motor feed driven system is also exploited to satisfy the requirement of maximum reciprocating speed up to 2m/s. Following plenty of specific design and performance analysis works, a prototype of supersonic grinding machine tool is finally developed. In the end, this paper also puts forward a number of further studies and prospective for the research activities on basis of the developed grinder.

High-Speed Grinding for Superalloy

2011 ◽  
Vol 487 ◽  
pp. 104-107
Author(s):  
B.F. Feng ◽  
Quan Fang Gai ◽  
Zheng Lei ◽  
Z.L. Su
Keyword(s):  
Friction Coefficient ◽  
High Speed ◽  
Removal Rate ◽  
Grinding Force ◽  
Speed Increase ◽  
Grinding Speed ◽  
Section Area ◽  
Force Ratio ◽  
High Speed Grinding ◽  
Single Grain

An investigation is reported on high-speed single-grain grinding for superalloy. The grooves’ morphology and area removal ratio, grinding force ratio, specific grinding force, and friction coefficient are studied. The area removal rate η increases with the grinding section area increasing. The plowing decreases with the grinding section area and grinding speed increase. Surface integrity can be improved under high speed and deep grinding. It is proved by experiments that the single-grain grinding friction coefficient decreases with the grinding speed increasing.

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