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Grinding force prediction and surface integrity analysis of Ti-4822 alloy formed by laser-directed energy deposition

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Abstract

Ti-4822 TiAl alloy is a typical intermetallic compound with great potential applications in aeronautics and astronautics and is widely available to high-pressure compressors and low-pressure turbine blades of aero-engines. Laser-directed energy deposition (LDED) is appropriate to form the Ti-4822 parts with complex shapes and structures. However, the LDED Ti-4822 alloy is a typical hard-brittle and difficult machining material with a poor rough surface and thermal conductivity, leading to poor grinding surface integrity. Therefore, in order to investigate and improve the grinding performance of LDED Ti-4822 alloy, a new prediction model of grinding force was proposed based on the combination of single-grain grinding and dynamic active grains grinding simulation. The influence of grinding parameters and grinding wheel category on grinding force, grinding force ratio, grinding surface morphology, grinding debris, and microhardness of LDED Ti-4822 alloy was analyzed by the single-factor and orthogonal experiments. The experimental results demonstrated that low feed speed, small grinding depth, and high grinding speed are beneficial to reduce grinding force and surface roughness (minimum 0.19 μm). Compared with the CBN wheel, the diamond wheel is more appropriate for grinding LDED Ti-4822 alloy because of a smoother grinding surface with less defects and lower wheel wear. Significant surface hardening will be generated by grinding LDED Ti-4822 alloy. The maximum Vickers hardness can reach 776.6 HV, and the mean depth of grinding hardened layer is 20 μm.

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Abbreviations

F n :

Normal grinding force

F t :

Tangential grinding force

F n/F t :

Grinding force ratio

v s :

Grinding wheel speed

a p :

Grinding depth

v w :

Feeding speed

σ s :

Stress of the material

ε :

Strain of the material

σ y :

Yield stress of the material

E :

Elastic modulus

B :

Strain hardening coefficient

n :

Strain hardening exponent

λ f :

Failure parameter

ε p :

Equivalent plastic strain

ε d :

Failure plastic strain

RP:

Load application point in FEM model

d μ :

Average granulometric size of the grains

d max :

Maximum granulometric size of the grains

d min :

Minimum granulometric size of the grains

d :

Granulometric size of grains

σ :

Standard deviation

V g :

Volume content of the grains

S :

Grinding wheel organization number

L r :

Average distance of the grains

l c :

Length of the grinding contact arc

D :

Diameter of grinding wheel

b :

Grinding width of grinding wheel

N x :

Number of grains along the circumferential direction

N y :

Number of grains along the axial direction

\({\mathrm{N}}_{{\mathrm{x}}{\mathrm{y}}}\) :

Total number of the grains in the grinding zone

h max :

Maximum protrusion height of grains

a g max :

Maximum undeformed chip thickness of grains

a s :

Protrusion height of the static active grains

N s :

Number of static active grains

N d :

Number of dynamic active grains

F t p :

Tangential grinding force simulated by simulation of single-grain grinding

F np :

Normal grinding force simulated by simulation of single-grain grinding

G(d):

Matrix of the grain size in the grinding zone

G(h):

Matrix of protrusion height of the grains

G(a s):

Matrix of protrusion height of the static active grains

G(a d):

Matrix of protrusion height of the dynamic active grains

G(a g max):

Matrix of maximum undeformed chip thickness of grains

a(n)g max :

Maximum undeformed chip thickness of the nth cutting grain

max(G(a g max)):

Maximum value of the thicknesses matrix of maximum undeformed chip

\({\mathrm{a}}_{{\mathrm{g}}\mathrm{max(}{\mathrm{n}}\mathrm{)}}^{*}\) :

Maximum undeformed chip thickness of the nth static active grain

\({\mathrm{a}}_{{\mathrm{gmax}}\mathrm{(}{\mathrm{n}}\mathrm{)}}\) :

Maximum undeformed chip thickness of the nth dynamic active grain

\({\mathrm{L}}_{\mathrm{(}{\mathrm{n}}\mathrm{ }{\mathrm{n}}\mathrm{-1}\mathrm{)}}^{*}\) :

Space between the nth static active grain and the (n − 1)th dynamic active grain

\({\mathrm{L}}_{\mathrm{(}{\mathrm{n}}\mathrm{ }{\mathrm{n}}\mathrm{-1)}}\) :

Space between the nth and the (n − 1)th dynamic active grains

a s ( n ) :

Protrusion height of the nth static active grain

a d ( n ) :

Protrusion height of the nth dynamic active grain

a d ( n -1) :

Protrusion height of the (n − 1)th dynamic active grain

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Funding

This research was financially supported by the National Nature Science Foundation (Grant No. 52005093) and the Fundamental Research Funds for the Central Universities (Grant No. N2203014), PR China. The authors also would like to thank the editors and reviewers for their elaborate work.

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  1. Dingkun Xu and Bo Xin (co-first authors) contributed equally to this work.

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China

    Dingkun Xu, Bo Xin, Xiaoqi Wang, Jiangyu Ren & Yadong Gong

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  1. Dingkun Xu
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Correspondence to Bo Xin.

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Xu, D., Xin, B., Wang, X. et al. Grinding force prediction and surface integrity analysis of Ti-4822 alloy formed by laser-directed energy deposition. Int J Adv Manuf Technol 129, 445–467 (2023). https://doi.org/10.1007/s00170-023-12255-7

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