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Study on the mechanism of chip forming and the microhardness of micro-grinding nickel-based single-crystal superalloy

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Abstract

Nickel-based single-crystal superalloy has no grain boundary, hence has excellent high-temperature mechanical properties and is the best option for the manufacturing of the blades of aero-engine and gas turbine. The removal mechanism of grinding traditional polycrystalline material is different from that of single-crystal material, but so far there are very few studies on grinding nickel-based single-crystal superalloy. To understand low-damage manufacturing of micro-grinding single-crystal parts, this paper first explored the chip-forming mechanism of micro-grinding nickel-based single-crystal superalloy; secondly, this paper analyzed the microstructure of micro-grinding sub-surface damage through the scanning electron microscope (SEM), then studied the microhardness on the sub-surface of grinding nickel-based single-crystal superalloy parts, and the surface-hardening phenomenon from the aspect of dislocation theory through the transmission electron microscope (TEM); finally, this paper investigated the microstructure of sub-surface recrystallization and the influence of recrystallization on the microhardness of the micro-grinding workpiece through simulating the high-temperature application environment, and the measures for controlling or inhibiting recrystallization of single-crystal parts were also discussed. The experiment results showed that the chip shape of grinding nickel-based single-crystal superalloy had the typical serrated structure due to the occurring of adiabatic shearing slippage, while the shearing slippage and the distortion took place in the sub-surface plastic deformation layer; the sawtooth degree of chips increased gradually with the spindle speed increasing; the feeding rate and grinding depth also had some effect on the sawtooth degree of the chips; the dislocation cell substructure appeared on the sub-surface of micro-grinding single-crystal superalloy, which improved the surface hardness of single-crystal parts; cellular recrystallization occurred on the sub-surface of the single-crystal parts after high-temperature treatment, which decreased the surface hardness of the workpiece and affected the service life of the parts; when the workpieces were precisely grinded using the micro-grinding tool electroplating 1000# abrasives at vs = 50,000 r/min, vw = 20 μm/s, and ap = 2 μm, followed by the annealing treatment at 760 °C for 4 h, the thickness of recrystallization layer significantly decreased, and the service life was improved. Therefore, these were good guidelines and references to the manufacturing of nickel-based single-crystal superalloy micro-workpiece.

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Funding

This work is supported by the Fundamental Research Funds for the Central Universities (N172303008 and N172303009), the Scientific Research Initiating Funds for Northeastern University at Qinhuangdao (XNY201806), and the National Natural Science Foundation of China (51775100, 51705069, and 51275083).

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Authors and Affiliations

  1. School of Control Engineering, Northeastern University at Qinhuangdao, Qinhuangdao, 066004, China

    Yunguang Zhou, Lianjie Ma & Li Zhang

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

    Yadong Gong, Guoqiang Yin & Yao Sun

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  1. Yunguang Zhou
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  2. Lianjie Ma
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  3. Yadong Gong
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  4. Li Zhang
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  6. Yao Sun
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Correspondence to Yunguang Zhou.

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Zhou, Y., Ma, L., Gong, Y. et al. Study on the mechanism of chip forming and the microhardness of micro-grinding nickel-based single-crystal superalloy. Int J Adv Manuf Technol 103, 281–295 (2019). https://doi.org/10.1007/s00170-019-03503-w

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