Surface modification through combination of finish turning with low plasticity burnishing and its effect on fatigue performance for Inconel 718

Hua, Yang; Wang, Qingqing; Wang, Bing; Hou, Xin

doi:10.1016/j.surfcoat.2019.07.057

Cited by 57 publications

(31 citation statements)

References 29 publications

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“…The surface integrity factors including surface roughness, residual stress, micro-hardness, and microstructure are considered the most relevant factors that will result in a failure of the turbine disk or shaft according to statistics [2]. It is noteworthy that, among the surface integrity factors, residual stress plays a key role in affecting the fatigue performance of components [3][4][5][6]. Compressive residual stress (CRS) is beneficial to improving fatigue performance [7][8][9], whereas induced tensile residual stress is usually detrimental to the fatigue life of components [10,11].…”

Section: Introductionmentioning

confidence: 99%

Effects of Machining Induced Residual Shear and Normal Stresses on Fatigue Life and Stress Intensity Factor of Inconel 718

Hua

Wang

2019

Applied Sciences

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Residual shear stresses and normal stresses induced by machining affect the fatigue performance of components. Thus, residual shear and normal stresses should be considered simultaneously when evaluating the influence of residual stress on fatigue performance. In the present paper, the influences of residual shear and normal stresses on the fatigue life and stress intensity factor (SIF) of turned Inconel 718 were investigated. Firstly, the cos α measurement method was utilized to calculate the residual shear stress and residual normal stress of turned Inconel 718. Then, the combined effects of residual shear and normal stresses on fatigue life were evaluated through uniaxial tension–tension fatigue tests. Thirdly, a prediction model for the SIF was proposed by taking the residual shear and normal stresses into account. Finally, the predicted SIF was validated by the published experimental data from the literature. The predicted results of the proposed model generally agreed well with the available experimental data.

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Section: Introductionmentioning

confidence: 99%

Effects of Machining Induced Residual Shear and Normal Stresses on Fatigue Life and Stress Intensity Factor of Inconel 718

Hua

Wang

2019

Applied Sciences

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“…Surface topography is one of the parameters of surface integrity, including roughness, waviness, and surface defects [ 14 ]. The surface topography mainly affects the contact condition and stress concentration, which will further affect the performance of the machined components [ 15 ]. In most mechanical parts, a smoother surface with lower surface roughness is usually preferred [ 16 ].…”

Section: Introductionmentioning

confidence: 99%

Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

et al. 2021

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Ball-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surface adhered damages will form on the machined surface under certain tool postures. It is determined that the formation of surface adhered damage is related to the material adhesion near the cutting edge and the cutting-into/out position within the tool per-rotation cycle. In order to analyze the cutting-into/out process more clearly under different tool postures, the projection models of the cutting edge and the cutter workpiece engagement on the contact plane are established; thus, the complex geometry problem of space is transformed into that of plane. Combined with the case of cutting-into/out, chip morphology, and surface morphology, the formation mechanism of surface adhered damage is analyzed. The analysis results show that the adhered damage can increase the height parameters Sku, Sz, Sp, and Sv of surface topographies. Sz, Sp, and Sv of the normal machined surface without damage (Sku ≈ 3) are about 4–6, 2–3, and 2–3 μm, while Sz, Sp, and Sv with adhered damage (Sku > 3) can reach about 8–20, 4–14, and 3–6 μm in down-milling and 10–25, 7–18, and 3–7 μm in up-milling. The feed direction should be selected along the upper left (Q2: β∈[0°, 90°]) or lower left (Q3: β∈[90°, 180°]) to avoid surface adhered damage in the down-milling process. For up-milling, the feed direction should be selected along the upper right (Q1: β∈(−90°, 0°]) or upper left (Q2: β∈[0°, 90°)).

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“…A novel sequential process incorporating the hard turning with low plasticity burnishing was developed to enhance the surface integrity and corrosion resistance of Cr-Ni alloys [16]; and the authors stated that the CS and surface finish have important roles in improving the corrosion resistance; and the integrative process could be applied to produce anti-corrosion components. Hua et al (2019) developed a hybrid operation comprising the finish turning and low plasticity burnishing to improve the surface integrity and fatigue characteristic of Inconel 718 [17]; the results showed that (1) the surface characteristics, including the topography, phase change, MH, CS, and SR were significantly improved, (2) the fatigue life can be enhanced by 82.4% with the aid of a hybrid approach, and (3) the fatigue life was primarily affected on the CS and SR. An integrative operation using the turning and roller burnishing was developed to machine the long shafts [18], in which the mathematical model of the SR was developed in terms of the slenderness of shaft (SS), burnishing force (BF), f, and S; and the results showed that (1) the f is the most effective parameter, followed by the BF, SS, and S, respectively; and (2) the hardness, residual stress, wear resistance, and fatigue strength of machined components were improved with the support of the proposed process.…”

Section: Introductionmentioning

confidence: 99%

“…16 The authors stated that the CS and surface finish have important roles in improving the corrosion resistance; and the integrative process could be applied to produce anti-corrosion components. Hua et al 17 developed a hybrid operation comprising the finish turning and low plasticity burnishing to improve the surface integrity and fatigue characteristic of Inconel 718. The results showed that the surface characteristics, including the topography, phase change, MH, CS, and SR were significantly improved.…”

Section: Introductionmentioning

confidence: 99%

Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

Nguyen

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The burnishing process is used to enhance the machining quality via improving the surface finish, surface hardness, wear-resistance, fatigue, and corrosion resistance, and it is mostly used in aerospace, biomedical, and automotive industries to improve reliability and performance of the component. The combined turning and burnishing process is therefore considered as an effective solution to enhance both machining quality and productivity. However, the trade-off analysis between energy consumption, surface characteristics, and production costs has not been well-addressed and investigated. This study presents an optimization of the compressed air assisted-turning-burnishing (CATB) process for aluminum alloy 6061, aimed to decrease the energy consumption as well as surface roughness and to enhance the Vicker hardness of the machined surface. The machining parameters for consideration include the machining speed, feed rate, depth of cut, burnishing force, and the ball diameter. The improved Kriging models were used to construct the relations between machining parameters and the technological response characteristics of the machined surface. The optimal machining parameters were obtained utilizing the desirability approach. The energy based-cost model was developed to assess the effectiveness of the proposed CATB process. The findings showed that the selected optimal outcomes of the depth of cut, burnishing force, diameter, feed rate, and machining speed are 0.66 mm, 196.3 N, 8.0 mm, 0.112 mm/rev, and 110.0 m/min, respectively. The energy consumption and surface roughness are decreased by 20.15% and 65.38%, respectively, while the surface hardness is improved by 30.05%. The production cost is decreased by 17.19% at the optimal solution. Finally, the proposed CATB process shows a great potential to replace the traditional techniques which are used to machine non-ferrous metals.

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Surface modification through combination of finish turning with low plasticity burnishing and its effect on fatigue performance for Inconel 718

Cited by 57 publications

References 29 publications

Effects of Machining Induced Residual Shear and Normal Stresses on Fatigue Life and Stress Intensity Factor of Inconel 718

Effects of Machining Induced Residual Shear and Normal Stresses on Fatigue Life and Stress Intensity Factor of Inconel 718

Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

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