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Description
Comprehensive reference on state-of-the-art aerospace materials, reviewing the latest developments in the field and providing guidance on machining challenges
Grinding of Single-Crystal Superalloys provides a comprehensive understanding of grinding technology for single-crystal nickel-based superalloys. It explores and analyzes grinding mechanisms and characteristics using both theoretical and simulation approaches. Grinding behavior in conventional and micro grinding processes are evaluated and compared.
The book assesses the surface integrity of single-crystal nickel-based superalloys under different grinding conditions. Simulation and theoretical models for predicting temperature and residual stresses in profile grinding, facilitating optimization, and control are summarized and validated.
Grinding of Single-Crystal Superalloys discusses sample topics including:
Grinding of Single-Crystal Superalloys is an essential reference for industry professionals and researchers seeking to understand the machining theory and practice of this important type of material, especially in the field of aerospace components manufacturing.
Table of Contents
Foreword xi
Preface xiii
Part I Grinding Mechanism of Single-crystal Nickel Alloy 1
1 Introduction 3
1.1 Development and Practical Application of Single-crystal Nickel Alloy 3
1.2 Advantages of Grinding Technology of Single-crystal Nickel Alloy 5
1.3 High-efficiency Grinding Technology Development of Single-crystal Nickel Alloy 7
1.4 Micro-grinding Technology Development of Single-crystal Nickel Alloy 18
1.5 Contents of this book 29
2 Removal Mechanism of Single-crystal Nickel Alloy in High-efficiency Grinding 33
2.1 Yield Criterion and Failure Criterion of Single-crystal Nickel Alloy 33
2.2 Simulation Model and Experiment Conditions 34
2.3 Simulation Results on Material Removal by Multi-abrasive Grains 34
2.4 Experimental Verification of Simulation Results 41
3 Plastic Deformation Mechanism of Single-crystal Nickel Alloy in Micro-grinding 45
3.1 Verification of Plastic Deformation Mechanism in Micro-grinding Materials 45
3.2 Microscale Debris in Micro-grinding of Single-crystal Nickel Alloy 49
Part II Grindability of Single-crystal Nickel Alloys 55
4 Grinding Force Evaluation 57
4.1 Grinding Force in Surface Grinding 57
4.2 Grinding Force in Profile Grinding 63
4.3 Grinding Force in Micro-grinding 67
5 Grinding Temperature Evaluation 77
5.1 Grinding Temperature in Surface Grinding 77
5.2 Grinding Temperature in Profile Grinding 81
5.3 Grinding Temperature in Micro-grinding 83
6 Grinding Wheel Wear Evaluation 93
6.1 Grinding Wheel Wear in Surface Grinding 93
6.2 Grinding Wheel Wear in Profile Grinding 102
6.3 Grinding Wheel Wear in Micro-grinding 111
Part III Surface Integrity by High-efficiency Grinding 129
7 Surface and Subsurface Microstructures in High-efficiency Grinding 131
7.1 Surface Microstructure and Surface Roughness in Surface Grinding 131
7.2 Subsurface Microstructure in Surface Grinding 133
7.3 Surface Microstructure and Surface Roughness in Profile Grinding 135
7.4 Subsurface Microstructure in Profile Grinding 138
8 Subsurface Nanostructures in High-efficiency Grinding 147
8.1 Subsurface Nanostructures in Profile Grinding 147
8.2 Analysis on Formation Mechanism of Nanostructures 152
8.3 Plastic Deformation and Microstructure Evolution of Single-crystal Nickel Superalloy 157
9 Microhardness and Residual Stresses in High-efficiency Grinding 167
9.1 Microhardness in Surface Grinding 167
9.2 Microhardness in Profile Grinding 167
9.3 Residual Stresses in Profile Grinding 169
10 Fretting Wear Behavior of the Machined Surface in High-efficiency Grinding 171
10.1 Friction Coefficient, Wear Volume, and Wear Rate During Fretting 171
10.2 Surface and Subsurface Microstructure During Fretting 174
10.3 Analysis of Fretting Wear Evolution on the Ground Surface 176
Part IV Surface Integrity in Micro-grinding 179
11 Surface Roughness in Micro-grinding 181
11.1 Theoretical Model of Surface Roughness 181
11.2 Influence of Grinding Parameters 184
11.3 Influence of Material Anisotropy of Nickel-based Single-crystal Superalloy 188
11.4 Influence of Different Crystal Orientations of Nickel-based Single-crystal Superalloy 191
11.5 Influence of Grinding Methods 194
12 Ground Surface and Subsurface Damage in Micro-grinding 197
12.1 Influence of Grinding Parameters 197
12.2 Influence of Working Fluid 200
13 Subsurface Microstructure and Recrystallization in Micro-grinding 203
13.1 Subsurface Microstructure in the Micro-grinding Process 203
13.2 Subsurface Recrystallization in Micro-grinding 210
Part V Simulation, Optimization, and Control in Grinding of Single-crystal Turbine Blade Root 219
14 Temperature Field in Grinding of Single-crystal Turbine Blade Root 221
14.1 FE Model for Grinding Temperature Simulation 221
14.2 Thermal Analysis for Grinding Temperature Simulation 223
14.3 Experimental Validation of Grinding Temperature 225
14.4 Temperature Simulation Results and Analysis 227
15 Residual Stress Field in Grinding of Single-crystal Turbine Blade Root 233
15.1 Mechanical Analysis for Residual Stress Simulation 233
15.2 Experimental Verification of Residual Stresses 238
15.3 Residual Stress Simulation Results and Analysis 239
15.4 Collaborative Manufacturing of Structure Shape and Surface Integrity 243
References 244
Index 247
