Skip to main content
SpringerLink
Log in

Experimental study of surface integrity in ultrasonic vibration–assisted milling of GH4169 nickel-based superalloy

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

GH4169 nickel-based high-temperature alloy demonstrates excellent mechanical, chemical, thermal shock, and mechanical load resistance properties. However, it is typically a difficult-to-machine material. Ultrasonic vibration–assisted milling can effectively solve the machining challenges of GH4169 nickel-based high-temperature alloy and improve surface integrity. Herein, the motion model of the tool-tip under ultrasonic vibration assistance is established. The tool-tip motion trajectory and chip separation law are analyzed. The effect of ultrasonic vibration on surface integrity is investigated through ultrasonic vibration–assisted milling experiments. The results show that residual surface stress stimulates at high milling speed, depth of cut, and feed rate, while it progressively decreases with ultrasonic amplitude. The machined surface hardening enhances with the addition of ultrasonic amplitude. The machined surface roughness increases with the growth of milling speed, feed rate, and ultrasonic amplitude, and decreases with the rise of cutting surface roughness increases with the addition of milling speed, feed rate, and ultrasonic amplitude, and falls with the rise of cutting depth.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

References

  1. Li S, Xiao G, Chen B, Zhuo X, Xu J, Huang Y (2022) Surface formation modeling and surface integrity research of normal ultrasonic assisted flexible abrasive belt grinding. J Manuf Process 80:232–246. https://doi.org/10.1016/j.jmapro.2022.05.045

    Article  Google Scholar 

  2. Wang Y, Pang S, Yan P, Jiao L, Qiu T, Zhou H, Wang X (2022) Experimental research on cryogenic cutting performance of Ni-based superalloy GH4169. Int J Adv Manuf Technol 121:379–392. https://doi.org/10.1007/s00170-022-09325-7

    Article  Google Scholar 

  3. Zhang X, Yang L, Wang Y, Lin B, Dong Y, Shi C (2020) Mechanism study on ultrasonic vibration assisted face grinding of Hard and brittle materials. J Manuf Process 50:520–527. https://doi.org/10.1016/j.jmapro.2020.01.003

    Article  Google Scholar 

  4. Xiao G, Chen B, Li S, Zhuo X, Zhao Z (2022) Surface integrity and fatigue performance of GH4169 superalloy using abrasive belt grinding. Eng Fail Anal 142:106764. https://doi.org/10.1016/j.engfailanal.2022.106764

    Article  Google Scholar 

  5. Yuan SM, Yan LT, Liu WD, Liu Q (2010) Investigation of machinability in minimum quantity lubrication milling of GH4169 aerospace superalloy. AMM 34–35:666–670. https://doi.org/10.4028/www.scientific.net/AMM.34-35.666

    Article  Google Scholar 

  6. Zhao C, Wang ZB, Wang XH, Xi W, Shi YY (2014) Research on cutting vibration in high-speed milling nickel-base superalloy. MSF 800–801:793–797. https://doi.org/10.4028/www.scientific.net/MSF.800-801.793

    Article  Google Scholar 

  7. Wang H, Zhou F, Han RD (2012) Research on cutting force and surface roughness in face milling Ni-based superalloy. AMR 588–589:1698–1701. https://doi.org/10.4028/www.scientific.net/AMR.588-589.1698

    Article  Google Scholar 

  8. Liu WW, Wan XS, Li XY, Yu Y, Wang DF (2013) A study of the sensitivity of parameters affecting surface roughness in high speed milling superalloy GH4169. AMR 711:143–148. https://doi.org/10.4028/www.scientific.net/AMR.711.143

    Article  Google Scholar 

  9. Akhtar W, Sun J, Chen W (2016) Effect of machining parameters on surface integrity in high speed milling of super alloy GH4169/Inconel 718. Mater Manuf Processes 31:620–627. https://doi.org/10.1080/10426914.2014.994769

    Article  Google Scholar 

  10. Li X, Ma S, Meng F (2015) Surface integrity of GH4169 affected by cantilever finish grinding and the application in aero-engine blades. Chin J Aeronaut 28:1539–1545. https://doi.org/10.1016/j.cja.2015.06.023

    Article  Google Scholar 

  11. Wang H, Lu Y, Liu JJ (2015) Study on tool wear in green milling Ni-based superalloy. AMR 1095:865–868. https://doi.org/10.4028/www.scientific.net/AMR.1095.865

    Article  Google Scholar 

  12. Li X, Guan C, Zhao P (2018) Influences of milling and grinding on machined surface roughness and fatigue behavior of GH4169 superalloy workpieces. Chin J Aeronaut 31:1399–1405. https://doi.org/10.1016/j.cja.2017.07.013

    Article  Google Scholar 

  13. Xu R, Zhou Y, Li X, Yang S, Han K, Wang S (2019) The effect of milling cooling conditions on the surface integrity and fatigue behavior of the GH4169 superalloy. Metals 9:1179. https://doi.org/10.3390/met9111179

    Article  Google Scholar 

  14. Miao Q, Ding W, Kuang W, Yang C (2020) Comparison on grindability and surface integrity in creep feed grinding of GH4169, K403, DZ408 and DD6 nickel-based superalloys. J Manuf Process 49:175–186. https://doi.org/10.1016/j.jmapro.2019.11.027

    Article  Google Scholar 

  15. Quan F, Chen Z, Li Q, Gao S (2020) Effects of process combinations of milling, grinding, and polishing on the surface integrity and fatigue life of GH4169 components. Proc Inst Mech Eng Part B-J Eng Manuf 234:538–548. https://doi.org/10.1177/0954405419868053

    Article  Google Scholar 

  16. Zhu P, Liu Z, Ren X, Wang B, Song Q (2021) Effects of sequential operation with heat treatment and mechanical milling on work hardening for superalloy GH4169. Metals 11:1367. https://doi.org/10.3390/met11091367

    Article  Google Scholar 

  17. Yao G, Liu Z, Song Q, Wang B, Cai Y (2022) Numerical prediction and experimental investigation of residual stresses in sequential milling of GH4169 considering initial stress effect. Int J Adv Manuf Technol 119:7215–7228. https://doi.org/10.1007/s00170-022-08740-0

    Article  Google Scholar 

  18. Chang B, Yi Z, Cao X, Duan J (2023) Defect suppression and grain refinement during ultrasonic vibration-assisted side milling of GH4169 superalloy. J Manuf Process 85:281–294. https://doi.org/10.1016/j.jmapro.2022.11.011

    Article  Google Scholar 

  19. Lotfi M, Amini S, Aghayar Z, Sajjady SA, Farid AA (2020) Effect of 3D elliptical ultrasonic assisted boring on surface integrity. Measurement 163:108008. https://doi.org/10.1016/j.measurement.2020.108008

    Article  Google Scholar 

  20. Wang F, Men X, Liu Y, Fu X (2020) Experiment and simulation study on influence of ultrasonic rolling parameters on residual stress of Ti-6Al-4V alloy. Simul Model Pract Theory 104:102121. https://doi.org/10.1016/j.simpat.2020.102121

    Article  Google Scholar 

  21. Chen Y, Su H, He J, Qian N, Gu J, Xu J, Ding K (2021) The effect of torsional vibration in longitudinal–torsional coupled ultrasonic vibration-assisted grinding of silicon carbide ceramics. Materials 14:688. https://doi.org/10.3390/ma14030688

    Article  Google Scholar 

  22. Yang Z, Zhu L, Ni C, Ning J (2019) Investigation of surface topography formation mechanism based on abrasive-workpiece contact rate model in tangential ultrasonic vibration-assisted CBN grinding of ZrO2 ceramics. Int J Mech Sci 155:66–82. https://doi.org/10.1016/j.ijmecsci.2019.02.031

    Article  Google Scholar 

  23. Shen JY, Wang JQ, Jiang B, Xu XP (2015) Study on wear of diamond wheel in ultrasonic vibration-assisted grinding ceramic. Wear 332–333:788–793. https://doi.org/10.1016/j.wear.2015.02.047

    Article  Google Scholar 

  24. Choi Y-J, Park K-H, Hong Y-H, Kim K-T, Lee S-W, Choi H-Z (2013) Effect of ultrasonic vibration in grinding; horn design and experiment. Int J Precis Eng Manuf 14:1873–1879. https://doi.org/10.1007/s12541-013-0253-1

    Article  Google Scholar 

  25. Deswal N, Kant R (2023) Hybrid turning process by interacting ultrasonic vibration and laser energies. Mater Manuf Processes 38:570–576. https://doi.org/10.1080/10426914.2022.2065014

    Article  Google Scholar 

  26. Airao J, Nirala CK, Bertolini R, Krolczyk GM, Khanna N (2022) Sustainable cooling strategies to reduce tool wear, power consumption and surface roughness during ultrasonic assisted turning of Ti-6Al-4V. Tribol Int 169:107494. https://doi.org/10.1016/j.triboint.2022.107494

    Article  Google Scholar 

  27. Arka GN, Sahoo SK, Iqbal MM, Singh S (2022) Acoustic horn tool assembly design for ultrasonic assisted turning and its effects on performance potential. Mater Manuf Processes 37:260–270. https://doi.org/10.1080/10426914.2021.2016819

    Article  Google Scholar 

  28. Bayat M, Amini S, Hadidi M (2021) Effect of ultrasonic-assisted turning on geometrical tolerances in Al 2024–T6. Mater Manuf Processes 36:1875–1886. https://doi.org/10.1080/10426914.2021.1926496

    Article  Google Scholar 

  29. Zamani M, Farahnakian M, Elhami S (2021) Employment of ultrasonic assisted turning in the fabrication of microtextures to improve the surface adhesion of the titanium implant. Proc Inst Mech Eng, Part B: J Eng Manuf 235:1983–1991. https://doi.org/10.1177/09544054211011029

    Article  Google Scholar 

  30. Zhang J, Du J, Li B, Su G (2023) Investigation on white layer formation in dry high-speed milling of nickel-based superalloy GH4169. Machines 11:406. https://doi.org/10.3390/machines11030406

    Article  Google Scholar 

  31. Xun L, Shuang M, Fanjun M (2015) Surface integrity of GH4169 affected by cantilever finish grinding and the application in aero-engine blades. Chin J Aeronaut 28:1539–1545. https://doi.org/10.1016/j.cja.2015.06.023

    Article  Google Scholar 

  32. Zeng Q, Liu G, Liu L, Qin Y (2015) Investigation into grindability of a superalloy and effects of grinding parameters on its surface integrity. Proc Inst Mech Eng Part B-J Eng Manuf 229:238–250. https://doi.org/10.1177/0954405414526384

    Article  Google Scholar 

  33. Li W, Chen Q, Wu J, Liu M, Ren Y, Ibrahim AMM (2022) Investigation of the effect of vibration characteristics on the grinding performance of aero-engine blade tip. Int J Adv Manuf Technol 120:4663–4679. https://doi.org/10.1007/s00170-022-09045-y

    Article  Google Scholar 

  34. Akhtar W, Sun J, Chen W (2016) Effect of machining parameters on surface integrity in high speed milling of super alloy GH4169/Inconel 718. Mater Manuf Process 31:620–627. https://doi.org/10.1080/10426914.2014.994769

    Article  Google Scholar 

  35. Wu M, Yu Y, Cheng Y, Li L, Zhao X (2018) Experimental investigation of chip plastic side flow in machining of GH4169 superalloy under high-pressure cooling. Ferroelectrics 530:82–96. https://doi.org/10.1080/00150193.2018.1453123

    Article  Google Scholar 

  36. Hansen N (2004) Hall-Petch relation and boundary strengthening. Scripta Mater 51:801–806. https://doi.org/10.1016/j.scriptamat.2004.06.002

    Article  Google Scholar 

Download references

Funding

This work was financially supported by the National Natural Science Foundation of China (52075439); the Doctoral Dissertation Innovation Fund of Xi’an University of Technology (252072203).

Author information

Authors and Affiliations

  1. School of Mechanical and Precision Instrument Engineering, Xi’an University of Technology, Xi’an, 710048, People’s Republic of China

    Jian Sun, Pengyang Li, Yunshuai Chen, Han Lu & Guoqing Chen

  2. Avic Shaanxi Aero Electric Co., Ltd, Xi’an, 710103, People’s Republic of China

    Shen Zhang

  3. Qinchuan Group (Xi’an) Technology Research Institute Co., Ltd, Xi’an, 710018, People’s Republic of China

    Ding Shao

Authors
  1. Jian Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Pengyang Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Shen Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yunshuai Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Han Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Guoqing Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Ding Shao
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Jian Sun, Pengyang Li and Yunshuai Chen developed the idea of the study and contributed to the acquisition and interpretation of data; Shen Zhang and Han Lu participated in design and coordination, and they helped to draft the manuscript; Guoqing Chena and Ding Shao provided critical review and substantially revised the manuscript. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Pengyang Li.

Ethics declarations

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sun, J., Li, P., Zhang, S. et al. Experimental study of surface integrity in ultrasonic vibration–assisted milling of GH4169 nickel-based superalloy. Int J Adv Manuf Technol 129, 5047–5058 (2023). https://doi.org/10.1007/s00170-023-12578-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12578-5

Keywords

Search

Navigation