Defect suppression and grain refinement during ultrasonic vibration-assisted side milling of GH4169 superalloy

Chang, Baoqi; Yi, Zhaoxi; Duan, Ji-an

doi:10.1016/j.jmapro.2022.11.011

Cited by 16 publications

(4 citation statements)

References 45 publications

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“…As shown in Figure 4, Chang et al selected a precision processing center to perform ultrasonic vibration assisted milling on nickel-based alloys, and found ultrasonic vibration assisted results in obvious grain refinement of the subsurface microstructure, and the degree of refinement presents a gradient change from the surface to the interior. In addition, the authors observed an orientation deviation of up to 293μm (at the dashed line in the Figure 4), indicating a large plastic deformation of the subsurface [41]. The phenomenon of micro-chip particles on the workpiece surface and the accumulation of tool edges is reduced [42].…”

Section: Surface Formation Mechanismmentioning

confidence: 94%

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Gu,

Wang,

et al. 2024

Intelligent and Sustainable Manufacturing

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Nickel-based alloys has important application value in modern industrial field, but there are a lot of problems that are difficult to solve in traditional processing, and it is a typical difficult-to-process material. In order to improve the machinability of nickel-based alloys, scholars try to use a variety of non-traditional processing methods to explore and study the processing of nickel-based alloys. In these studies, ultrasonic vibration assisted processing technology and minimum quantity lubrication (MQL) processing technology can achieve remarkable results. The intermittent separation cutting characteristics of ultrasonic vibration assisted processing technology can improve the processing quality by changing the tool path, while minimum quantity lubrication processing technology can improve the lubrication effect of cutting, combining ultrasonic vibration assisted MQL processing leverages the benefits of both methods, resulting in improved machinability and expanded application of nickel-based alloys. Summarize the current research status on the machining mechanism of nickel-based alloys assisted by ultrasonic vibration and micro lubrication, and anticipate its developmental trends. This provides a reference for future research on the efficient machining mechanisms and practical applications of nickel-based alloys.

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Section: Surface Formation Mechanismmentioning

confidence: 94%

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Gu,

Wang,

et al. 2024

Intelligent and Sustainable Manufacturing

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“…Under higher amplitude conditions, longitudinal torsional UVAM generated over 20% larger residual stresses and thicker (up to 5.4 µm) subsurface deformation layers than CM. Chang et al [78] investigated an ultrasonic vibrationassisted side milling process by clamping an ultrasonic vibration system on the tool spindle, with the goal of decreasing machining flaws during side milling of Inconel 718 superalloy. A schematic of the UVAM system and surface formation is shown in figure 6.…”

Section: Tool Ultrasonic Vibration-assisted Millingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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“…Also, the high cutting force, high cutting temperature, and difficult chip breaking further lead to severe tool wear, damage, chip sticking, and other problems. As a result, it is difficult to ensure the quality and accuracy of the processed surface of the GH4169 superalloy [4][5][6]. Cutting under high-pressure cooling conditions contributes to a better quality of processed surface than conventional cooling.…”

Section: Introductionmentioning

confidence: 99%

Optimization of surface roughness and machining parameters for turning superalloy GH4169 under high-pressure cooling

Zhang¹,

Wu²,

Liu³

et al. 2021

Surf. Topogr.: Metrol. Prop.

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Superalloys are important structural materials in the aerospace and petrochemical industries. Because of their excellent fatigue and oxidation resistance, superalloys are usually used predominantly in rotor and turbine components. The requirement of good surface quality and high-precision processes has been widely concerned. High-pressure cooling is a commonly used auxiliary processing technology in the metal cutting field, which can efficiently improve the quality of the processed surface. It is of great significance to study the surface roughness of GH4169 processed by cutting under high-pressure cooling conditions. First, the single-factor and orthogonal experiment methods were used. The single factors, interaction effect, and quadratic effect of cutting parameters and cooling pressure were analyzed. Then, the multiple linear regression method was adopted to establish the prediction model for surface roughness of GH4169, and the accuracy of this model was verified. Finally, according to the prediction model, the machining parameters were optimized and verified. The results indicated that the proposed model was accurate and reliable, which could be used to optimize the machining parameters. The optimal parameter combination was achieved, with the cutting speed of 154 m/min, the feed rate of 0.10 mm/r, the cutting depth of 0.46 mm, and the cooling pressure of 52 bar. Under this parameter setting, the prediction error was 4.20%, and the surface roughness was 34.92% less than that obtained under the actually recommended machining parameters. The above results will provide theoretical guidance for the parameter optimization of cutting superalloy under high-pressure cooling conditions and quality control of the processed surface.

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Defect suppression and grain refinement during ultrasonic vibration-assisted side milling of GH4169 superalloy

Cited by 16 publications

References 45 publications

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Optimization of surface roughness and machining parameters for turning superalloy GH4169 under high-pressure cooling

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