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Study on machining performance in grinding of Ni-base single crystal superalloy DD5

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Abstract

The Ni-base single crystal superalloy DD5 is commonly employed in critical parts of turbine blades and turbine disks in aeronautical engines. To improve the surface machining quality, single-factor experiments were carried out to investigate the changes of grinding force, surface morphology, and chip morphology under different grinding conditions (dry, conventional flood, minimum quantity lubrication). The experiments showed that the conventional flood lubrication and minimum quantity lubrication (MQL) could enormously reduce the surface roughness, grinding force, and work-hardened layer thickness of DD5. At the depth of 5 ~ 15 μm, the DD5 subsurface microhardness decreased sharply with the increase of depth, and the microhardness under different grinding conditions was in the order of dry grinding, conventional flood, and MQL. However, at the depth of 20 ~ 150 μm, the DD5 subsurface microhardness tended to equilibrate and fluctuate around 540 HV. In addition, compared with dry grinding, the degree of chip serration was obvious in flood or MQL environment, and its chip formation frequency fluctuated less and chip formation was stable. Within the experimental parameters, the MQL grinding machining method obtained the lowest surface roughness and the highest surface quality with the lowest associated cost, which is the ideal grinding and cooling lubrication method for the Ni-base single crystal superalloy.

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All data and materials used to produce the results in this article can be obtained upon request from the corresponding authors.

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Funding

This work was supported by the National Natural Science Foundation of China (Nos. U1908230 and 51775100), the Science and Technology Research Project of the Educational Department of Liaoning Province (Nos. LJKZ0384 and L2017LQN024), and the Talent Scientific Research Fund of LNPU (No. 2021XJJL-007).

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Authors and Affiliations

  1. School of Mechanical Engineering, Liaoning Petrochemical University, Fushun, 113001, China

    Ming Cai, Tao Zhu, Xingjun Gao, Yongfei Yan & Lei Zeng

  2. School of Innovation and Entrepreneurship, Liaoning Petrochemical University, Fushun, 113001, China

    Ning Yu

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  1. Ming Cai
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Contributions

Ming Cai: writing–original draft, software, investigation, visualization. Tao Zhu: writing–original draft, review and editing, conceptualization, funding, visualization. Xingjun Gao: conceptualization, methodology, formal analysis. Yongfei Yan: supervision, investigation, methodology. Ning Yu: data curation, formal analysis. Lei Zeng: data curation, formal analysis.

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Correspondence to Xingjun Gao.

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Cai, M., Zhu, T., Gao, X. et al. Study on machining performance in grinding of Ni-base single crystal superalloy DD5. Int J Adv Manuf Technol 120, 7657–7671 (2022). https://doi.org/10.1007/s00170-022-09256-3

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