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Multi-scale modeling reveals microstructural and mechanical evolution in GH4169 and DD5 nickel-based superalloys during grinding

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Abstract

This study delves into the grinding-induced microstructural and mechanical evolution in high-entropy nickel-based superalloys GH4169 and DD5, underscoring their distinct behaviors under varying machining conditions. Leveraging “Random Substitution” in Material Studio, the research developed intricate atomic models to accurately depict the complex chemical compositions and microstructures of these superalloys. Neper software was employed for multi-scale modeling, specifically analyzing the unit cells of GH4169. A critical focus was placed on the effects of key grinding parameters—depth, spindle speed, and feed rate—on the crystallographic deformation of GH4169, contrasting it with the response of DD5. The study highlighted a notable transition in GH4169’s material removal mechanism from plastic flow to chip spallation at enhanced grinding depths and feed rates, while maintaining lattice integrity at higher grinding speeds. GH4169 consistently demonstrated greater tangential and normal forces during grinding compared to DD5, reflecting intricate machining complexities. The differential crystal orientations between these superalloys significantly impacted the grinding force distribution and heat dissipation during the process. This comprehensive analysis provides pivotal insights into the micro-level grinding process parameters, enriching both theoretical and practical understanding of material machinability in advanced manufacturing contexts. The study’s novelty lies in its application of detailed atomic models and multi-scale modeling to uncover subtle microstructural and mechanical dynamics during the grinding of superalloys.

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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 (NO. U1908230), the Natural Science Foundation of Liaoning Province (NO. 2023-BS-185), the Science and Technology Research Project of the Educational Department of Liaoning Province (NO. LJKZ0384), 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

    Minghui Chen, Ming Cai, Qiang Gong & Minglei Zhang

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

    Yadong Gong

  3. Institute of Mechanical Manufacturing Technology, China Academy of Engineering Physics, Mianyang, 201800, China

    Tao Zhu

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  1. Minghui Chen
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  2. Ming Cai
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  3. Yadong Gong
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Contributions

Minghui Chen: writing—original draft, software, investigation, and visualization. Ming Cai: writing—original draft, review, and editing, conceptualization, funding, and visualization. Yadong Gong: supervision, investigation, and methodology. Qiang Gong: data curation and formal analysis. Tao Zhu: data curation and formal analysis. Minglei Zhang: data curation and formal analysis.

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Correspondence to Ming Cai.

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Chen, M., Cai, M., Gong, Y. et al. Multi-scale modeling reveals microstructural and mechanical evolution in GH4169 and DD5 nickel-based superalloys during grinding. Int J Adv Manuf Technol 132, 1391–1410 (2024). https://doi.org/10.1007/s00170-024-13419-9

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