single-au.php

IJAT Vol.16 No.1 pp. 43-51
doi: 10.20965/ijat.2022.p0043
(2022)

Technical Paper:

Effect of Types of Grinding Fluid on Grinding Characteristics of CMSX4

Tatsuki Ikari*,†, Takayuki Kitajima*, and Akinori Yui**

*Mechanical Systems Engineering, National Defense Academy of Japan
1-10-20 Hashirimuzu, Yokosuka, Kanagawa 239-8686, Japan

Corresponding author

**Department of Mechanical Engineering, Kanagawa University, Yokohama, Japan

Received:
June 7, 2021
Accepted:
September 14, 2021
Published:
January 5, 2022
Keywords:
grinding, nickel superalloy, grinding fluid
Abstract

Nickel-based heat-resistant alloys are widely used for fabricating the turbine blades in gas turbine engines. An increase in the number of such engines operated by air carriers will increase the demand for high-efficiency machining of nickel-based heat-resistant alloys. However, the high-efficiency grinding of nickel-based heat-resistant alloys is challenging because of their low thermal conductivity and thermal diffusivity, high chemical activity, large work-hardening properties, and high-temperature strength. In this work, the authors propose a high-efficiency grinding technique that uses speed-stroke grinding of nickel-based heat-resistant alloys, and aim to clarify the optimum grinding conditions for the proposed grinding method. The workpiece material is CMSX4 used for the turbine blades. A Cubitron + WA grinding wheel and WA grinding wheel mounted on a linear motor-driven surface grind machines are used for grinding, and the grinding force, surface roughness, and grinding ratio are investigated with the removal rate maintained constant. Two types of grinding fluid are prepared: solution and soluble. From the experiments, it is found that wet grinding features a lower grinding force, smaller surface roughness, and higher grinding ratio when compared to dry-cut grinding. The improvement in the grinding ratio at high table speeds is significant, and it is found to be greater for the soluble-type fluid than for the solution-type fluid.

Cite this article as:
T. Ikari, T. Kitajima, and A. Yui, “Effect of Types of Grinding Fluid on Grinding Characteristics of CMSX4,” Int. J. Automation Technol., Vol.16, No.1, pp. 43-51, 2022.
Data files:
References
  1. [1] E. O. Ezugwu, “Key improvements in the machining of difficult-to-cut aerospace superalloys,” Int. J. of Machine Tools and Manufacture, Vol.45, Issues 12-13, pp. 1353-1367, 2005.
  2. [2] S. L. Soo, R. Hood, D. K. Aspinwall, W. E. Voice, and C. Sage, “Machinability and surface integrity of RR1000 nickel based superalloy,” CIRP Annals, Vol.60, Issue 1, pp. 89-92, 2011.
  3. [3] G. Cerri, A. Giovannelli, L. Battisti, and R. Fedrizzi, “Advances in effusive cooling techniques of gas turbines,” Applied Thermal Engineering, Vol.27, Issue 4, pp. 692-698, 2007.
  4. [4] A. D. Antony et al., “Structural dynamic analysis of turbine blade,” 2017 IOP Conf. Ser., Mater. Sci. Eng., Vol.247, 012007, 2017.
  5. [5] C.-W. Dai, W.-F. Ding, Y.-J. Zhu, J.-H. Xu, and H.-W. Yu, “Grinding temperature and power consumption in high speed grinding of Inconel 718 nickel-based superalloy with a vitrified CBN wheel,” Precision Engineering, Vol.52, pp. 192-200, 2018.
  6. [6] F. Klocke, A. Klink, D. Veselovac, D. K. Aspinwall, S. L. Soo, M. Schmidt, J. Schilp, G. Levy, and J.-P. Kruth, “Turbomachinery component manufacture by application of electrochemical, electro-physical and photonic processes,” CIRP Annals, Vol.63, Issue 2, pp. 703-726, 2014.
  7. [7] F. Klocke, S. L. Soo, B. Karpuschewski, J. A. Webster, D. Novovic, A. Elfizy, D. A. Axinte, and S. Tönissen, “Abrasive machining of advanced aerospace alloys and composites,” CIRP Annals, Vol.64, Issue 2, pp. 581-604, 2015.
  8. [8] Y. Yamabe-Mitarai, Y. Ro, T. Maruko, and H. Harada, “Ir-base refractory superalloys for ultra-high temperatures,” Met. Trans., 29A, pp. 537-549, 1998.
  9. [9] “Superalloys and High Temperature Materials Group.” https://www.nims.go.jp/eng/research/group/superalloys-and-high-temperature-materials/index.html [Accessed May 30, 2021]
  10. [10] H. Harada, “High Temperature Materials for Gas Turbines: The Present and Future,” Proc. of the Int. Gas Turbine Congress 2003, pp. 2-7, 2003.
  11. [11] I. A Choudhury and M. A. El-Baradie, “Machinability of nickel-base super alloys: a general review,” J. of Materials Processing Technology, Vol.77, Issues 1-3, pp. 278-284, 1998.
  12. [12] Q. Miao, W. Ding, W. Kuang, and C. Yang, “Comparison on grindability and surface integrity in creep feed grinding of GH4169, K403, DZ408 and DD6 nickel-based superalloys,” J. of Manufacturing Processes, Vol.49, pp. 175-186, 2020.
  13. [13] W. Österle and P. X. Li, “Mechanical and thermal response of a nickel-base superalloy upon grinding with high removal rates,” Materials Science and Engineering: A, Vol.238, Issue 2, pp. 357-366, 1997.
  14. [14] D. K. Aspinwall, S. L. Soo, D. T. Curtis, and A. L. Mantle, “Profiled Superabrasive Grinding Wheels for the Machining of a Nickel Based Superalloy,” CIRP Annals, Vol.56, Issue 1, pp. 335-338, 2007.
  15. [15] S. Li, Y. Wu, and M. Nomura, “Effect of grinding wheel ultrasonic vibration on chip formation in surface grinding of Inconel 718,” The Int. J. of Advanced Manufacturing Technology, Vol.86, pp. 1113-1125, 2016.
  16. [16] A. Thakur and S. Gangopadhyay, “State-of-the-art in surface integrity in machining of nickel-based super alloys,” Int. J. of Machine Tools and Manufacture, Vol.100, pp. 25-54, 2016.
  17. [17] Y. Kita, M. Ido, and S. Hata, “The mechanism of metal removal by an abrasive tool,” Wear, Vol.47, Issue 1, pp. 185-193, 1978.
  18. [18] Y. Kita, M. Ido, and S. Hata, “Mechanism of Chip Formation,” J. of the Japan Society of Precision Engineering, Vol.43, Issue 512, pp. 944-949, 1977 (in Japanese).
  19. [19] K. Ono, S. Kawamura, M. Kitano, and T. Shimamune, “Theoretical Cutting Engineering” Gendai Kougaku-sha, 1979 (in Japanese).
  20. [20] K. Ono, “Surface finish method No.2,” Bicycle Production Technology, No.48, pp. 38-45, 1958 (in Japanese).

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, Opera.

Last updated on Oct. 04, 2022