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Process parameter optimization and surface integrity evolution in the high-speed grinding of TiAl intermetallics based on grey relational analysis method

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Abstract

TiAl intermetallic alloy (Ti-45Al-2Mn-2Nb) is a typical hard-to-machine material which was used in the aero-engines. To study its machinability, the high-speed grinding experiments were conducted using electroplated diamond abrasive wheel. The effects of grinding parameters (e.g., grinding wheel speed vs, infeed speed vw, and grinding depth ap) on the grinding force and temperature were discussed. Then, the grey relational analysis (GRA) and variance analysis method were utilized to analyze the results. In addition, the evolution of the surface integrity was researched to characterize the machinability comprehensively. The results show that ap had the greatest effect on the normal grinding force and grinding temperature of TiAl intermetallics, while as for the tangential grinding force, vs did. When vs increases from 60 to 120 m/s, the residual stress along and perpendicular to the grinding direction decreased by 54.7% and 10%, respectively. The maximum microhardness of the ground surface increased to 620 HV0.05 at this moment, which was 1.55 times larger than that of the original matrix. Additionally, the chips morphology indicated that the adverseness of the low temperature plasticity of TiAl intermetallic alloy could be well overcome through the high-speed grinding tests. Finally, according to the GRA, the combination of vs=90 m/s, vw=0.5 m/min, and ap=0.1 mm was selected as the optimal parameter combination.

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All data generated or analyzed during this study are included in the present article.

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Funding

This work was financially supported by the National Natural Science Foundation of China (Nos. 51921003 and 51775275), National Key Laboratory of Science and Technology on Helicopter Transmission (Nanjing University of Aeronautics and Astronautics) (No. HTL-A-20G01), Major Special Projects of Aero-engine and Gas Turbine (No. 2017-VII-0002-0095), and the Foundation of Graduate Innovation Center in NUAA (No. KFJJ20200501).

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Author notes

  1. Tao Chen and Yejun Zhu contributed equally to this work.

Authors and Affiliations

  1. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Tao Chen, XinXin Xi & Wenfeng Ding

  2. College of Engineering, Nanjing Agricultural University, Nanjing, 210032, China

    Yejun Zhu

  3. School of Mechanical Engineering, Yancheng Institute of Technology, Yancheng, 224051, China

    Haixiang Huan

Authors
  1. Tao Chen
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  2. Yejun Zhu
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  3. XinXin Xi
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  4. Haixiang Huan
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  5. Wenfeng Ding
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Contributions

Tao Chen conceived the analysis and wrote the manuscript. Yejun Zhu collected the data and revised the manuscript. XinXin Xi and Haixiang Huan performed the experiment. Wenfeng Ding provided supervision on experimentation and manuscript preparation.

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Correspondence to Wenfeng Ding.

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Chen, T., Zhu, Y., Xi, X. et al. Process parameter optimization and surface integrity evolution in the high-speed grinding of TiAl intermetallics based on grey relational analysis method. Int J Adv Manuf Technol 117, 2895–2908 (2021). https://doi.org/10.1007/s00170-021-07882-x

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