com
The Seventeenth CIRP Conference on Electro Physical and Chemical Machining (ISEM)
Machining Research Group, School of Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham, B15 2TT, UK
b
Turbines, Rolls-Royce plc, Derby, DE24 9BD, UK
c
Element Six Ltd., Shannon, Co. Clare, Republic of Ireland
d
Hardinge Machine Tools, Whetstone, Leicester, LE8 6BD, UK
e
Saint-Gobain Diamantwerkzeuge GmbH & Co. KG, Schtzenwall 13-17, D-22844 Norderstedt, Germany
f
Systems, Power & Energy Division, School of Engineering, University of Glasgow, Glasgow, G12 8QQ, UK
* Corresponding author. Tel.: +44-121-414-4196; fax: +44-121-414-4201.E-mail address: s.l.soo@bham.ac.uk.
Abstract
The paper details the effects of depth of cut and vibration amplitude when ultrasonic assisted (US) creep feed grinding Inconel 718
with an open structured alumina based wheel. The workpiece was actuated at a constant frequency (~20.5kHz) via a block
sonotrode attached to a 1kW piezoelectric transducer-generator system. A full factorial experimental array comprising 12 tests was
conducted involving variation in depth of cut (0.1, 0.5 and 1.0mm), amplitude of vibration (high and low) and grinding condition
(with and without vibration). Wheel speed and table feed were fixed at 30m/s and 600mm/min respectively for all tests. Application
of ultrasonic vibration resulted in reductions in vertical (Fv) and horizontal (Fh) force components by up to 28% and 37%
respectively, however greater wheel wear (30-60% lower G-ratio) occurred under hybrid operation due to increased grit/bond
fracture. SEM micrographs of the slots machined with US assistance revealed higher levels of side flow/ploughing in comparison to
standard creep feed ground specimens. Additionally, more overlapping grit marks were visible on surfaces subject to ultrasonic
assisted grinding. Increasing amplitude of vibration produced lower grinding forces (up to 30% for Fv and 43% for Fh) but higher
workpiece surface roughness (up to 24%). Topographic maps of grinding wheel surface replicas indicated that use of US vibration
generally led to an increase in the number of active cutting points on the wheel.
2013 The Authors. Published by Elsevier B.V. Open access under CC BY-NC-ND license.
2013 The Authors. Published by Elsevier B.V. Selection and/or peer-review under responsibility of Professor Bert Lauwers
Selection and/or peer-review under responsibility of Professor Bert Lauwers
Keywords: Grinding; nickel; ultrasonics; vibration.
1. Introduction
Nickel based superalloys are used extensively in the
hotter sections of gas turbine engines, as they are able to
maintain their strength and corrosion resistance (at
temperatures above ~700C) better than other metallic
alloys. As a result of continuous development over the
last ~60 years, the range of superalloys in use is far more
comprehensive than generally appreciated [1], however
a common feature is their relatively poor machinability
as detailed by a number of researchers [2-3]. Despite
recent
gains
in
abrasive
machining
performance/productivity through the development and
use of more open structured wheel systems/grit
2212-8271 2013 The Authors. Published by Elsevier B.V. Open access under CC BY-NC-ND license.
Selection and/or peer-review under responsibility of Professor Bert Lauwers
doi:10.1016/j.procir.2013.03.044
616
Depth of cut, ae
(mm)
Amplitude of
vibration
Vibration
1
2
3
4
5
6
7
8
9
10
11
12
0.1
0.1
0.1
0.1
0.5
0.5
0.5
0.5
1.0
1.0
1.0
1.0
0
High
0
Low
0
High
0
Low
0
High
0
Low
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
617
Fv at ae=0.1mm
Fh at ae=0.1mm
Fv at ae=0.5mm
Fh at ae=0.5mm
1200
1000
Fv at ae=1mm
Fh at ae=1mm
800
600
400
200
0
US US
US US
US US
US US
US US
US US
OFF ON
OFF ON OFF ON OFF ON OFF ON OFF ON
(Low)
(High)
(High)
(Low)
(Low)
(High)
Depth of cut
0.1 mm
0.5 mm
1.0 mm
Fig. 3. Vertical (Fv) and horizontal (Fh) grinding forces under different
grinding conditions
Fv
Fh
55.8*
W/P
Ra
22.1
W/P Graphite
Sa
Sa
20.8* 57.7*
G-ratio
91.1* 54.9*
Amplitude (Amp)
1.4
13.3
1.4
25.0*
55.2*
28.9*
Vibration (Vib)
4.8*
12.8
22.2*
0.4
6.2
4.7*
aeAmp
0.6
8.6
1.9
10.8
3.9
1.0
aeVib
0.5
2.9
8.4
6.3
9.4
0.3
AmpVib
0.0
2.7
3.7
21.1
0.7
1.3
aeAmpVib
1.6
4.8
6.6
14.3
3.8
6.1
25
20
30
25
20
15
15
10
10
0
US US
US US
OFF ON
OFF ON
(Low)
(High)
Depth of cut
0.1 mm
US US
US US
US US
US US
OFF ON
OFF ON OFF ON OFF ON
(Low)
(High)
(High)
(Low)
0.5 mm
1.0
1.0 mm
When ultrasonic actuation was employed, wheel Gratio reduced by 30-60% in 5 out of 6 tests. The radial
component (in the Z-direction) of ultrasonic vibration
imparted a higher mechanical load on the grits together
with a load-relieving phase [16]. This led to micro-
Ra-end at ae=0.5mm
Ra-start at ae=1mm
Ra-middle at ae=1mm
Ra-end at ae=1mm
0.5
0.0
US US
US US
OFF ON
OFF ON
(High)
(Low)
Depth of cut
US US
US US
US US
US US
OFF ON
OFF ON OFF ON OFF ON
(High)
(Low)
(Low)
(High)
0.5 mm
0.1 mm
1.0 mm
0.1 mm
8
G-ratio
Ra-start at ae=0.1mm
Ra-middle at ae=0.1mm
Ra-end at ae=0.1mm
Ra-start at ae=0.5mm
Ra-middle at ae=0.5mm
0.1 1.5
mm
30
618
Sa at ae=0.1mm
St at ae=0.1mm
Sz at ae=0.1mm
Sa at ae=0.5mm
St at ae=0.5mm
Sz at ae=0.5mm
Sa at ae=1mm
St at ae=1mm
Sz at ae=1mm
US US
US US
OFF ON
OFF ON
(High)
(Low)
US US
US US
US US
US US
OFF ON
OFF ON OFF ON OFF ON
(High)
(Low)
(Low)
(High)
0.5 mm
1.0 mm
619
0 2.5
Sds at ae=0.1mm
Sds at ae=0.5mm
Sds at ae=1mm
0
0
025
2.0
20
1.5
15
1.0
10
0.5
0.0
US US
US US
OFF ON
OFF ON
(Low)
(High)
Depth of cut
0.1 mm
US US
US US
US US
US US
OFF ON
OFF ON OFF ON OFF ON
(Low)
(High)
(High)
(Low)
0.5 mm
1.0 mm
620
Acknowledgements
We gratefully acknowledge the help and support from
the University of Glasgow for facilities to measure the
vibrational amplitude of the block sonotrode. We are
also indebted to Mr. M. Prokic of MP Interconsulting for
References
[1]