Experimental investigation on high-shear and low-pressure grinding process for Inconel718 superalloy

• Published in: International journal of advanced manufacturing technology Vol. 107; no. 7-8; pp. 3425 - 3435
• Main Authors: Tian, Yebing, Li, Linguang, Liu, Bing, Han, Jinguo, Fan, Zenghua
• Format: Journal Article
• Language: English
• Published: London Springer London 01.04.2020; Springer Nature B.V
• Subjects: CAE) and Design; Computer-Aided Engineering (CAD; Engineering; Grinding tools; Grinding wheels; Industrial and Production Engineering; Low pressure; Mechanical Engineering; Media Management; Newtonian fluids; Nickel base alloys; Non Newtonian fluids; Original Article; Shear; Shear thickening (liquids); Superalloys; Surface defects; Surface roughness; Thickening; Tool wear; Wear particles; Workpieces; Nickel-based superalloy; Precision grinding; Flexible composites; Grinding tools; High-shear and low-pressure grinding
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-020-05284-z

In this work, we reported a novel grinding method with high tangential grinding force and low normal grinding force using specially developed grinding tools. The tools were made of flexible composites based on the principle of liquid body armor and the shear thickening mechanism of non-Newtonian fluid. During grinding, abrasive particles are capable of generating a “hydro-cluster effects” under reverse tangential load, which lead to the decreased normal grinding force and the increased tangential grinding force. Hence, workpiece materials are removed under “high-shear and low-pressure” grinding mode. A serial of grinding experiments were carried out on Inconel718. The results showed that the novel grinding tool had an excellent grinding performance on Inconel718 workpieces. The value of surface roughness decreased from Ra 473.7 nm to Ra 153.0 nm under the optimal grinding parameters, i.e., wheel speed of 1 m/s, workpiece speed of 2000 mm/min, and grinding depth of cut of 180 μm. The surface defects of the Inconel718 workpiece were gradually removed. Meanwhile, the uniformed grinding textures were generated. The surface of the grinding tool had residual wear debris, and there was a little loss of grains after 240 grinding cycles.