Numerical analysis and experimental validation of surface roughness and morphology in honing of Inconel 718 nickel-based superalloy

doi:10.1007/s40436-022-00422-0

Advances in Manufacturing ›› 2023, Vol. 11 ›› Issue (1): 130-142.doi: 10.1007/s40436-022-00422-0

• • 上一篇

Numerical analysis and experimental validation of surface roughness and morphology in honing of Inconel 718 nickel-based superalloy

Chang-Yong Yang^1,2, Zhi Wang², Hao Su², Yu-Can Fu^1,2, Nian-Hui Zhang², Wen-Feng Ding^1,2

1. Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People's Republic of China;
2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People's Republic of China

收稿日期:2021-12-01 修回日期:2022-06-09 发布日期:2023-02-16
通讯作者: Chang-Yong Yang,E-mail:yangchy@nuaa.edu.cn E-mail:yangchy@nuaa.edu.cn
作者简介:Chang-Yong Yang is currently an associate professor of mechanical engineering at Nanjing University of Aeronautics and Astronautics, People's Republic of China. His research interests include honing and grinding technology of difficultto-cut materials, super hard abrasive tools and machining process simulation;
Zhi Wang is currently a master candidate of mechanical engineering at Nanjing University of Aeronautics and Astronautics, People's Republic of China. His research interest is high efficiency and precision honing technology of difficult-to-cut materials;
Hao Su is currently a PhD candidate of mechanical engineering at Nanjing University of Aeronautics and Astronautics, People's Republic of China. His research interest is hole machining technology of high efficiency and precision;
Yu-Can Fu is currently a professor of mechanical engineering and doctoral supervisor at Nanjing University of Aeronautics and Astronautics, People's Republic of China. His research interests include high efficiency machining technology, super abrasive tool technology and green cooling technology;
Nian-Hui Zhang is currently a master candidate of mechanical engineering at Nanjing University of Aeronautics and Astronautics, P. R. China. His research interest is the honing technology of high efficiency and precision;
Wen-Feng Ding is currently a professor of mechanical engineering and doctoral supervisor at Nanjing University of Aeronautics and Astronautics, People's Republic of China. His research interests include grinding technology and equipment, superhard abrasive tools, machining process simulation and control technology.

Numerical analysis and experimental validation of surface roughness and morphology in honing of Inconel 718 nickel-based superalloy

Chang-Yong Yang^1,2, Zhi Wang², Hao Su², Yu-Can Fu^1,2, Nian-Hui Zhang², Wen-Feng Ding^1,2

1. Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People's Republic of China;
2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People's Republic of China

Received:2021-12-01 Revised:2022-06-09 Published:2023-02-16
Supported by:
The authors gratefully acknowledge the financial support of this research by the National Natural Science Foundation of China (Grant No. 52075252).

摘要/Abstract

摘要： Honing is an important technology for machining onboard system parts. The parts are usually made of difficult-to-machining materials, e.g., Inconel 718 superalloy. Honing can improve the finishing accuracy and surface quality. However, the selection of the honing parameters was primarily based on the results of a large number of experiments. Therefore, the establishment of a reliable model is needed to predict the honed surface roughness and morphology, and offers a theoretical direction for the choice of parameters. In the present study, a numerical simulation model was constructed for analysis of the honing process by Python. The oilstone, workpiece surface morphology and motion trajectory were discretized by Python, and the machined surface was obtained by trajectory interference. Firstly, based on the statistical analysis of the surface topography of oilstone, the shape of grains was simplified and the surface topography of oilstone was built accordingly. Then, the initial surface morphology of the workpiece was constructed and the trajectory of grains on the workpiece surface was analyzed, which showed the distribution of the removed material. Meanwhile, the plastic deformation of material was analyzed in the simulation model. The critical depth of three stages of contact between grains and workpiece was calculated by the theoretical formula: scratching, ploughing and cutting. By analyzing the distribution of bulge, the plastic deformation in ploughing and cutting stage was studied. Further, the simulated results of honed surface roughness and morphology were validated and agreed reasonably well with the honing experiment. Finally, the effects of honing process parameters, including grain size, tangential speed, axial speed, radial speed and abrasive volume percentage, on the surface roughness of the workpiece were analyzed by the simulation model.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00422-0

关键词: Numerical analysis, Surface roughness, Plastic deformation, Morphology

Abstract: Honing is an important technology for machining onboard system parts. The parts are usually made of difficult-to-machining materials, e.g., Inconel 718 superalloy. Honing can improve the finishing accuracy and surface quality. However, the selection of the honing parameters was primarily based on the results of a large number of experiments. Therefore, the establishment of a reliable model is needed to predict the honed surface roughness and morphology, and offers a theoretical direction for the choice of parameters. In the present study, a numerical simulation model was constructed for analysis of the honing process by Python. The oilstone, workpiece surface morphology and motion trajectory were discretized by Python, and the machined surface was obtained by trajectory interference. Firstly, based on the statistical analysis of the surface topography of oilstone, the shape of grains was simplified and the surface topography of oilstone was built accordingly. Then, the initial surface morphology of the workpiece was constructed and the trajectory of grains on the workpiece surface was analyzed, which showed the distribution of the removed material. Meanwhile, the plastic deformation of material was analyzed in the simulation model. The critical depth of three stages of contact between grains and workpiece was calculated by the theoretical formula: scratching, ploughing and cutting. By analyzing the distribution of bulge, the plastic deformation in ploughing and cutting stage was studied. Further, the simulated results of honed surface roughness and morphology were validated and agreed reasonably well with the honing experiment. Finally, the effects of honing process parameters, including grain size, tangential speed, axial speed, radial speed and abrasive volume percentage, on the surface roughness of the workpiece were analyzed by the simulation model.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00422-0

Key words: Numerical analysis, Surface roughness, Plastic deformation, Morphology

Chang-Yong Yang, Zhi Wang, Hao Su, Yu-Can Fu, Nian-Hui Zhang, Wen-Feng Ding. Numerical analysis and experimental validation of surface roughness and morphology in honing of Inconel 718 nickel-based superalloy[J]. Advances in Manufacturing, 2023, 11(1): 130-142.

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Numerical analysis and experimental validation of surface roughness and morphology in honing of Inconel 718 nickel-based superalloy

Numerical analysis and experimental validation of surface roughness and morphology in honing of Inconel 718 nickel-based superalloy

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