An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels

doi:10.1007/s40436-020-00305-2

Advances in Manufacturing ›› 2020, Vol. 8 ›› Issue (2): 160-176.doi: 10.1007/s40436-020-00305-2

An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels

Ben-Kai Li, Qing Miao, Min Li, Xi Zhang, Wen-Feng Ding

National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People's Republic of China

收稿日期:2019-10-04 修回日期:2020-02-18 出版日期:2020-06-25 发布日期:2020-06-08
通讯作者: Wen-Feng Ding E-mail:wfding@nuaa.edu.cn
基金资助:
This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 51775275 and 51921003), National Major Science and Technology Project (Grant No. 2017-VII-0002-0095), Funding for Outstanding Doctoral Dissertation in NUAA (Grant No. BCXJ19-06), the Six Talents Summit Project in Jiangsu Province (Grant No. JXQC-002) and Fundamental Research Funds for the Central Universities (Grant No. NP2018110).

An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels

Ben-Kai Li, Qing Miao, Min Li, Xi Zhang, Wen-Feng Ding

National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People's Republic of China

Received:2019-10-04 Revised:2020-02-18 Online:2020-06-25 Published:2020-06-08
Contact: Wen-Feng Ding E-mail:wfding@nuaa.edu.cn
Supported by:
This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 51775275 and 51921003), National Major Science and Technology Project (Grant No. 2017-VII-0002-0095), Funding for Outstanding Doctoral Dissertation in NUAA (Grant No. BCXJ19-06), the Six Talents Summit Project in Jiangsu Province (Grant No. JXQC-002) and Fundamental Research Funds for the Central Universities (Grant No. NP2018110).

摘要/Abstract

摘要： In this study, the machined surface quality of powder metallurgy nickel-based superalloy FGH96 (similar to Rene88DT) and the grinding characteristics of brown alumina (BA) and microcrystalline alumina (MA) abrasive wheels were comparatively analyzed during creep feed grinding. The influences of the grinding parameters (abrasive wheel speed, workpiece infeed speed, and depth of cut) on the grinding force, grinding temperature, surface roughness, surface morphology, tool wear, and grinding ratio were analyzed comprehensively. The experimental results showed that there was no significant difference in terms of the machined surface quality and grinding characteristics of FGH96 during grinding with the two types of abrasive wheels. This was mainly because the grinding advantages of the MA wheel were weakened for the difficult-to-cut FGH96 material. Moreover, both the BA and MA abrasive wheels exhibited severe tool wear in the form of wheel clogging and workpiece material adhesion. Finally, an analytical model for prediction of the grinding ratio was established by combining the tool wear volume, grinding force, and grinding length. The acceptable errors between the predicted and experimental grinding ratios (ranging from 0.6 to 1.8) were 7.56% and 6.31% for the BA and MA abrasive wheels, respectively. This model can be used to evaluate quantitatively the grinding performance of an alumina abrasive wheel, and is therefore helpful for optimizing the grinding parameters in the creep feed grinding process.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00305-2

关键词: Creep feed grinding, Powder metallurgy nickel-based superalloy, Surface quality, Alumina abrasive wheel, Tool wear

Abstract: In this study, the machined surface quality of powder metallurgy nickel-based superalloy FGH96 (similar to Rene88DT) and the grinding characteristics of brown alumina (BA) and microcrystalline alumina (MA) abrasive wheels were comparatively analyzed during creep feed grinding. The influences of the grinding parameters (abrasive wheel speed, workpiece infeed speed, and depth of cut) on the grinding force, grinding temperature, surface roughness, surface morphology, tool wear, and grinding ratio were analyzed comprehensively. The experimental results showed that there was no significant difference in terms of the machined surface quality and grinding characteristics of FGH96 during grinding with the two types of abrasive wheels. This was mainly because the grinding advantages of the MA wheel were weakened for the difficult-to-cut FGH96 material. Moreover, both the BA and MA abrasive wheels exhibited severe tool wear in the form of wheel clogging and workpiece material adhesion. Finally, an analytical model for prediction of the grinding ratio was established by combining the tool wear volume, grinding force, and grinding length. The acceptable errors between the predicted and experimental grinding ratios (ranging from 0.6 to 1.8) were 7.56% and 6.31% for the BA and MA abrasive wheels, respectively. This model can be used to evaluate quantitatively the grinding performance of an alumina abrasive wheel, and is therefore helpful for optimizing the grinding parameters in the creep feed grinding process.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00305-2

Key words: Creep feed grinding, Powder metallurgy nickel-based superalloy, Surface quality, Alumina abrasive wheel, Tool wear

Ben-Kai Li, Qing Miao, Min Li, Xi Zhang, Wen-Feng Ding. An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels[J]. Advances in Manufacturing, 2020, 8(2): 160-176.

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An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels

An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels

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