Effects of processing parameters on the surface quality of wrought Ni-based superalloy by ultrasonic-assisted electrochemical grinding

Ma, Yucai; Yin, Yingyue; Zhang, Jianhua; Huo, Jinxing

doi:10.1007/s00170-022-09562-w

Cited by 7 publications

(4 citation statements)

References 28 publications

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“…Figure 7 shows graphically the effects of applied voltage on MRR and surface roughness at the constant value of grinding wheel speed 1,500 rpm and machining time 60 s. The MRR increases with the applied voltage when the applied voltage increases from 9 to 17 V. According to Faraday’s law, the MRR is proportional to the current density. Because the applied voltage directly affects the current density of the machining area, the MRR increases with the increase of the applied voltage (Ma et al , 2022). It can be seen from Figure 7(a) that the MRR increased by 0.138 g/min when the applied voltage is increased from 9 to 17 V in the 15 Wt.% NaCl electrolyte.…”

Section: Resultsmentioning

confidence: 99%

Study of machining performance for electrochemical grinding of difficult-to-cut alloy U71Mn

Li,

Zhang,

Zhang

et al. 2024

ILT

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Purpose This study aims to apply an electrochemical grinding (ECG) technology to improve the material removal rate (MRR) under the premise of certain surface roughness in machining U71Mn alloy. Design/methodology/approach The effects of machining parameters (electrolyte type, grinding wheel granularity, applied voltage, grinding wheel speed and machining time) on the MRR and surface roughness are investigated with experiments. Findings The experiment results show that an electroplated diamond grinding wheel of 46# and 15 Wt.% NaNO3 + 10 Wt.% NaCl electrolyte is more suitable to be applied in U71Mn ECG. And the MRR and surface roughness are affected by machining parameters such as applied voltage, grinding wheel speed and machining time. In addition, the maximum MRR of 0.194 g/min is obtained with the 15 Wt.% NaCl electrolyte, 17 V applied voltage, 1,500 rpm grinding wheel speed and 60 s machining time. The minimum surface roughness of Ra 0.312 µm is obtained by the 15 Wt.% NaNO3 + 10 Wt.% NaCl electrolyte, 13 V applied voltage, 2,000 rpm grinding wheel speed and 60 s machining time. Originality/value Under the electrolyte scouring effect, the products and the heat generated in the machining can be better discharged. ECG has the potential to improve MRR and reduce surface roughness in machining U71Mn. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2023-0341/

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Section: Resultsmentioning

confidence: 99%

Study of machining performance for electrochemical grinding of difficult-to-cut alloy U71Mn

Li,

Zhang,

Zhang

et al. 2024

ILT

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“…In recent years, the introduction of ultrasonic vibration in grinding is a new method to improve the grinding quality of di cult-to-machine materials such as titanium alloys, nickel-based high-temperature alloys, ceramics and other materials in the aerospace industry [18][19][20][21][22][23][24][25][26]. Studies have shown that ultrasonic vibration-assisted grinding (UVAG) can introduce high-frequency micro-amplitude vibration, change the relative motion trajectory between the abrasive grain and the workpiece, so that the relative percentage of abrasive grain rubbing, ploughing, cutting effect changes, which can effectively reduce the grinding force and the grinding temperature, and enhance the integrity of the surface of the workpiece [26][27][28][29][30].…”

Section: Introductionmentioning

confidence: 99%

Wear mechanism of aggregated cBN grains during single-grain ultrasonic vibration-assisted grinding of γ-TiAl alloys

Song,

Zhao,

Ding

et al. 2024

Preprint

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In this study, the wear mechanism of single aggregated cubic boron nitride (AcBN) grain during ultrasonic vibration-assisted grinding is investigated. The single AcBN grinding experiment are conducted under conventional grinding and ultrasonic vibration-assisted grinding on gamma titanium-aluminum intermetallic compounds, and the grain wear mechanism is comprehensively revealed by observing the radial wear height, normal force, average volume pile-up ratio, and morphology evolution of the grains with different maximum undeformed chip thicknesses, grinding speeds, and ultrasonic amplitudes. The experimental results show that the introduction of ultrasonic vibration produces periodic vibration of the workpiece in the tangential direction, which can produce intermittent dissociative behavior and effectively reduce normal force and average volume pile-up ratio of single AcBN grains when grinding, but also makes the instantaneous maximum undeformed chip thickness increase and introduces the periodic impact force, which accelerates the radial wear height of the AcBN grains. In addition, the ultrasonic vibration can effectively reduce the material adhesion in the AcBN grains surface and cause it to continuously undergo micro-fracture has better self-sharpening ability. In addition, excessive ultrasonic amplitude will lead to AcBN grains to occur macro-fracture and the expansion of bond cracks lead to abrasive grains pulling out, losing partial grinding ability.

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“…Ultrasonic-assisted welding is one of the important applications of ultrasonic technology with a high frequency (15 kHz to 40 kHz) and a low amplitude [2]. Different kinds of ultrasonic vibration-assisted machining processes, such as milling [3,4], turning [5,6], grinding [7,8], drilling [9,10], deburring [11,12], diamond machining (cutting) [13,14], electrical discharge machining (EDM) [15,16], abrasive water jet machining [17], hybrid laser-and ultrasonic-assisted machining [18,19], and surface finishing [20][21][22], etc., have been developed in recent years. The materials processed by the ultrasonic-assisted machining processes [3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20][21][22], in general, can be classified as brittle materials, hard-machining metallic materials, composite materials, and non-metallic materials, etc.…”

Section: Introductionmentioning

confidence: 99%

“…The damage characteristics of ultrasonic vibration-assisted grinding of a C/SIC composite material has been studied in [7]. The effects of processing parameters on the surface quality of wrought Ni-based superalloy by ultrasonic-assisted electrochemical grinding has been investigated in [8]. The chip generation mechanism of Inconel 718 with ultrasonic-assisted drilling by step drill has been studied in [9].…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic-Assisted Surface Finishing of STAVAX Mold Steel Using Lab-Made Polishing Balls on a 5-Axis CNC Machining Center

Shiou,

Pan,

Ding

et al. 2023

Materials

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The inconvenience of conventional wool ball polishing is that the surface finishing process should be equipped with a slurry container. The main objective of this research is to develop an ultrasonic-assisted surface finishing process for STAVAX mold steel on a 5-axis CNC machining center, by using new lab-made rubber polishing balls containing the abrasive aluminum oxide instead of the traditional wool ball polishing. In total, five types (type A to type E) of new rubber-matrixed polishing balls with a composite of nitrile butadiene rubber (NBR), an abrasive of aluminum oxide, and an additive of silicon dioxide have been developed. The performance of the composites with different grain sizes (0.05 μm to 3 μm) and concentrations of the abrasive of aluminum oxide have been investigated. The effects of multiple polishing passes on the surface roughness improvement for the lab-made polishing balls have also been investigated in this study. A surface roughness of Ra 0.027 μm on average was achieved by using the multiple polishing process of E-C-B-A. The volumetric wear of the lab-made polishing balls, using ultrasonic vibration-assisted polishing, can be improved from about 12.64% (type A) to 65.48% (type E) compared with the non-vibration-assisted polishing. The suitable combination of the ultrasonic vibration-assisted polishing parameters were an amplitude of 10 μm, a frequency of 23 kHz, a spindle speed of 5000 rpm, a feed rate of 60 mm/min, a stepover of 20 μm, a penetration depth of 180 μm, and a polishing pass of E-C-B-A, based on the experimental results. The surface roughness improvement on a test carrier with a saddle surface has also been presented by using the ultrasonic vibration-assisted polishing with the lab-made polishing balls.

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Effects of processing parameters on the surface quality of wrought Ni-based superalloy by ultrasonic-assisted electrochemical grinding

Cited by 7 publications

References 28 publications

Study of machining performance for electrochemical grinding of difficult-to-cut alloy U71Mn

Study of machining performance for electrochemical grinding of difficult-to-cut alloy U71Mn

Wear mechanism of aggregated cBN grains during single-grain ultrasonic vibration-assisted grinding of γ-TiAl alloys

Ultrasonic-Assisted Surface Finishing of STAVAX Mold Steel Using Lab-Made Polishing Balls on a 5-Axis CNC Machining Center

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