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Study on grinding performance during ultrasonic vibration-assisted grinding ultra-high strength steels

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Abstract

Super high-strength steel has an important demand in manufacturing key components inside gear transmission systems of heavy-duty helicopter owing to its superior comprehensive mechanical property. However, the high-performance machining of super high-strength steel is confronted with great challenges owing to the high cutting force, serious tool wear, and impoverished machining quality. Comparative trials in grinding ultra-high strength steel under conventional grinding (CG) and ultrasonic vibration-assisted grinding (UVAG) processes were conducted with white alumina (WA) and microcrystalline alumina (MA) wheels. Grinding performances, including grinding forces, force ratio, ground surface quality, and abrasive wheel morphologies, were discussed in detail. Experimental results show that the separation property between wheels and workpiece in UVAG process contributes to alter the material removal process, reducing the chip clogging and adhesion. In addition, the micro-fracture of abrasive grains can effectively improve the self-sharpening ability of abrasive wheels. UVAG possesses a shorter grinding scratch owing to the ultrasonic vibration than that of CG, which is beneficial to improve machining quality under the same wheel. Meanwhile, in comparison of WA wheels, MA wheels have the narrower grinding marks and better surface quality, which is due to the sharp edges produced by its higher strength, toughness, and excellent self-sharpening.

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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. 92160301, 92060203, 52175415, and 52205475), the Science Center for Gas Turbine Project (Nos. P2022-AB-IV-002–001 and P2023-B-IV-003–001), the Natural Science Foundation of Jiangsu Province (No. BK20210295), the Superior Postdoctoral Project of Jiangsu Province (No. 2022ZB215), the National Key Laboratory of Science and Technology on Helicopter Transmission (Nanjing University of Aeronautics and Astronautics) (No. HTL-A-22G12), and the Foundation of Graduate Innovation Center in NUAA (No. XCXJH20220503).

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Authors and Affiliations

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

    Ming Han, Wenfeng Ding, Junshuai Zhao & Biao Zhao

  2. Communication University of China, Nanjing College of Art and Design, Nanjing, 210016, China

    Yi Tang

  3. AECC Zhongchuan Transmission Machinery Co., Ltd, Changsha, 410200, China

    Guoliang Liu, Mingming Deng & Menglan Tang

Authors
  1. Ming Han
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  2. Yi Tang
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  3. Wenfeng Ding
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  4. Junshuai Zhao
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  5. Biao Zhao
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  6. Guoliang Liu
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  7. Mingming Deng
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  8. Menglan Tang
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Contributions

Ming Han: experimentation, data curation, and writing the original draft. Yi Tang: data collection. Wenfeng Ding: data collection and manuscript revision. Junshuai Zhao: experimentation and methodology. Biao Zhao: supervision, conceptualization, and methodology. Guoliang Liu: resources. Menglan Tang: funding acquisition. Mingming Deng: funding acquisition.

Corresponding author

Correspondence to Wenfeng Ding.

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Han, M., Tang, Y., Ding, W. et al. Study on grinding performance during ultrasonic vibration-assisted grinding ultra-high strength steels. Int J Adv Manuf Technol 128, 3673–3684 (2023). https://doi.org/10.1007/s00170-023-12147-w

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  • DOI: https://doi.org/10.1007/s00170-023-12147-w

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