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Investigation of grindability and surface integrity in creep feed grinding of GH738 alloy using different grinding wheels

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Abstract

GH738 superalloy offers exceptional material properties at elevated temperature and is widely applied to the critical components of aero-engines and gas turbine. However, high strength and poor thermal conductivity bring significant challenges for the machining and surface qualities of GH738 superalloy. In this work, the creep feed grinding performance of GH738 was investigated. The variation laws and formation mechanism of surface integrity were explored with three common types of alumina grinding wheels under various grinding parameters. The experimental results showed that there is considerable impact of grinding parameters on the grinding force and grinding temperature. The stronger coupling of thermal and mechanical aggravates worse surface integrity. The propensity of grinding burn could be more sensitive when the maximum undeformed chip thickness is greater than 0.45–0.5 μm. With the material removal rate in the range of 0.83–1.67 mm3/mm·s, surface defects are visible, and the thickness of plastic deformation layer is about 4–6 μm. In addition, the surface quality ground by the white and pink fused alumina mixed abrasive grinding wheel (WA-PA) is slightly superior to that of the WA and BA grinding wheels. Finally, the grinding parameters for creep feed grinding GH738 are recommended as vw ∈ [50, 150] mm/min, vs ∈ [25, 35] m/s, and ap ∈ [0.2, 0.6] mm.

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Funding

The authors received financial support provided by the National Natural Science Foundation of China (grant numbers 51905442, 91860206, and 92160301) and the National Major Science and Technology Projects of China (grant number 2017-VII-0002–0095).

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Yihui Song, Kaining Shi, Zhe He, Zhaoqing Zhang & Yaoyao Shi

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Yihui Song, Kaining Shi, Zhe He, Zhaoqing Zhang & Yaoyao Shi

  3. State Key Laboratory of Cemented Carbide, Zhuzhou, 412000, Hunan, China

    Kaining Shi & Yaoyao Shi

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  1. Yihui Song
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Contributions

All the authors contributed to the study conception and design. Yihui Song performed the machining experiment and wrote the first draft of the manuscript. Kaining Shi proposed the conception of this work and performed the data analyses. Zhe He contributed significantly to analysis and language editing. Zhaoqing Zhang contributed to manuscript preparation. Yaoyao Shi reviewed and edited the manuscript. All the authors read and approved the final manuscript.

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Correspondence to Kaining Shi.

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Song, Y., Shi, K., He, Z. et al. Investigation of grindability and surface integrity in creep feed grinding of GH738 alloy using different grinding wheels. Int J Adv Manuf Technol 123, 4153–4169 (2022). https://doi.org/10.1007/s00170-022-10497-5

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