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Analytical and experimental study on micro-grinding surface-generated mechanism of DD5 single-crystal superalloy using micro-diamond pencil grinding tool

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Abstract

Single-crystal superalloy is characterized by no grain boundary and widely used in the aviation and aerospace industry due to its high creep strength and high thermal fatigue resistance, especially applications in aero engine necessitate numerous micro-scale structures made of single-crystal superalloy material with high-dimensional accuracy and surface quality. Micro-grinding as one of micro-precision machining technology is capable to fabricate micro-parts and structures with high machining precision and quality. In this work, a series of diamond micro-pencil grinding tool (MPGT) with diameter ranged from about 100 to 800 μm are firstly prepared by hybrid processes. The surface-generated mechanism of micro-grinding process associated with effects of length ratio of rubbing, ploughing and chip forming were explored based on analytical and experimental investigations. In addition, a novel analytical force model for the DD5 material machined by MPGT is developed considering variable size effect under different length proportion, protrusion height distribution of MPGT and material mechanical properties, which can more accurately agree well with the measured results compared with the traditional micro-grinding force model. This study enabled an in-depth understanding of mechanical behaviour characteristics, surface formation and material removal mechanism under microscopic scale of single-crystal superalloy involved in micro-grinding.

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Abbreviations

v s t :

The workpiece speed in turning mm/min (Fig. 1)

v s e :

The workpiece speed in LS-WEDT mm/min (Fig. 1)

a pe :

The cutting depth in LS-WEDT/mm (Fig. 1)

p av :

The average abrasive protrusion height/μm (Fig. 4)

h e, p ,m :

Rubbing/ploughing critical/undeformed/chip thickness/μm (Fig. 5)

r :

The grinding edge rounded radius/μm (Eq. 7)

L (i) ,L :

The grain(i) edge distance/the average grinding edge distance/μm (Eqs. 2, 4)

v w ,s :

The feed velocity/spindle speed in micro-grinding μm/s;r/min (Fig. 1)

E * :

The relative Young's modulus/Gpa (Eq. 7)

a,b :

The upper and lower protrusion height limits/μm (Eq. **

Pmax :

The maximum normal load/N (Eq. 5)

α, β :

Instantaneous front angle/friction angle (Eq. 7)

η,ζ :

Instantaneous shear angle/the angle between the resultant force and feed velocity vw (Fig. 7)

α 0 :

Chip forming critical angle; (Fig. 7)

ψ :

Grain and workpiece contact angle (Eqs. 11, 12)

τ s :

Shear strength Gpa

K :

The coefficient of the workpiece (Eq. 12)

Ω :

The angle between the central axis and the edge (Eq. 12)

F f,c, chf b :

The ball abrasive friction/chip friction/cutting/force (Eqs. 10, 12, 14)

F f,c, chf ,t :

The triangular abrasive friction/chip friction/cutting/force (Eqs. 10, 12, 14)

A :

Contact area; (Eqs. 11, 13)

V g :

The abrasive particles volume fraction (Eq. 20)

λ1 ,2,3 :

Modification coefficient in rubbing/ploughing/chip forming

v wt :

The feed velocity in turning mm/min (Fig. 1)

v w e :

The feed velocity in LS-WEDT mm/min (Fig. 7)

d sp :

Micro-abrasives matrix diameter/μm (Fig. 7)

l e, p ,c, k :

Rubbing/ploughing/chip forming/total/contact length/μm (Fig. 5)

a p,g :

The average/single grain/cutting depth in micro-grinding/μm (Fig. 1)

Md :

Modification coefficient

d s :

Micro-abrasive tool diameter/μm (Eq. 3)

S (i) :

The continuous grain(i) movement distance/μm (Eqs. 2, 3)

E g , w :

The grain/workpiece Young's modulus/Gpa (Eq. 7)

υ g , w :

The grain/workpiece Poisson ratio (Eq. 7)

ε :

The strain rate (Eq. 9)

a 0 :

Elastic recovery height/μm (Eq. 10)

p g (i) ,p av :

The grain(i) protrusion height/the average protrusion height/μm (Eqs. 1, 6)

θ :

The grain top angle (Fig. 7)

λ:

Geometric correction factor (Eqs. 10, 12, 14)

H :

Vickers hardness; (Eq. 10)

ξ :

The proportional coefficient; 0.2 ~ 0.5 (Eq. 12)

μ :

Coefficient of friction (Eqs. 10, 12, 14)

F f,c, chf ,c :

The cone abrasive friction/chip friction/cutting/force (Eqs. 10, 12, 14)

N d :

Dynamic effective blade number; (Eq. 20)

w :

The micro-grinding width (Eq. 20)

p g max :

Maximum protrusion height/μm

F n,t :

Normal/Tangential/force/μm (Eqs. 21, 23)

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Acknowledgements

The authors would like to thank the support of the China Postdoctoral Science Foundation (no. 2019M661111), the Fundamental Research Funds for the Central Universities (no. N180303028), the National Natural Science Foundation of China (nos. 51775100, 52005092) and the Fundamental Research Funds for the Central Universities (no. N2003024).

Funding

This study was funded by the China Postdoctoral Science Foundation (no. 2019M661111), the Fundamental Research Funds for the Central Universities (no. N180303028), the National Natural Science Foundation of China (no. 51775100) and the Fundamental Research Funds for the Central Universities (no. N2003024).

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Sun, Y., Su, Z., Gong, Y. et al. Analytical and experimental study on micro-grinding surface-generated mechanism of DD5 single-crystal superalloy using micro-diamond pencil grinding tool. Archiv.Civ.Mech.Eng 21, 21 (2021). https://doi.org/10.1007/s43452-020-00163-6

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