DOCSLIB.ORG

University of Birmingham a Study on Ultrasonic Assisted Creep Feed

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
University of Birmingham a Study on Ultrasonic Assisted Creep Feed University of Birmingham A study on ultrasonic assisted creep feed grinding of nickel based superalloys Bhaduri, Debajyoti; Soo, Sein; Aspinwall, David; Novovic, Donka; Harden, Peter; Bohr, S.; Martin, D. DOI: 10.1016/j.procir.2012.04.064 License: Creative Commons: Attribution (CC BY) Document Version Publisher's PDF, also known as Version of record Citation for published version (Harvard): Bhaduri, D, Soo, S, Aspinwall, D, Novovic, D, Harden, P, Bohr, S & Martin, D 2012, 'A study on ultrasonic assisted creep feed grinding of nickel based superalloys', Procedia CIRP, vol. 1, pp. 359-364. https://doi.org/10.1016/j.procir.2012.04.064 Link to publication on Research at Birmingham portal General rights Unless a licence is specified above, all rights (including copyright and moral rights) in this document are retained by the authors and/or the copyright holders. The express permission of the copyright holder must be obtained for any use of this material other than for purposes permitted by law. •Users may freely distribute the URL that is used to identify this publication. •Users may download and/or print one copy of the publication from the University of Birmingham research portal for the purpose of private study or non-commercial research. •User may use extracts from the document in line with the concept of ‘fair dealing’ under the Copyright, Designs and Patents Act 1988 (?) •Users may not further distribute the material nor use it for the purposes of commercial gain. Where a licence is displayed above, please note the terms and conditions of the licence govern your use of this document. When citing, please reference the published version. Take down policy While the University of Birmingham exercises care and attention in making items available there are rare occasions when an item has been uploaded in error or has been deemed to be commercially or otherwise sensitive. If you believe that this is the case for this document, please contact [email protected] providing details and we will remove access to the work immediately and investigate. Download date: 30. Sep. 2021 Available online at www.sciencedirect.com Procedia CIRP 1 ( 2012 ) 359 – 364 5th CIRP Conference on High Performance Cutting 2012 A study on ultrasonic assisted creep feed grinding of nickel based superalloys D. Bhaduria, S.L. Sooa,*, D.K. Aspinwalla, D. Novovicb, P. Hardenc, S. Bohrd, D. Martine aMachining Research Group, School of Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham, B15 2TT, UK bTurbines, Rolls-Royce plc, Derby, DE24 9BD, UK cElement Six Ltd., Shannon, Co. Clare, Republic of Ireland dSaint-Gobain Diamantwerkzeuge GmbH & Co. KG, Schützenwall 13-17, D-22844 Norderstedt, Germany eHardinge Machine Tools, Whetstone, Leicester, LE8 6BD, UK * Corresponding author. Tel.: +44-121-414-4196; fax: +44-121-414-4201.E-mail address: [email protected]. Abstract The paper initially reviews research relating to ultrasonic (US) assisted grinding of various workpiece materials. Results from experimental trials to evaluate the influence of applying US vibration when creep feed grinding Inconel 718 with an open structured, alumina based grinding wheel (POROS 2) are then presented. A full factorial experimental array comprising 18 runs was conducted involving variation in wheel speed (30, 35 and 40m/s), table speed (200, 250 and 300mm/min) and grinding condition (with and without vibration). For tests with US vibration, the workpiece was actuated at a constant frequency (~20kHz) via a specially designed block sonotrode attached to a 1kW piezoelectric transducer-generator system. Reductions in vertical (FV) and horizontal (FH) grinding force components of up to 23% and 43% for FV and FH respectively and surface roughness (Sa) of the ground slots by up to 45% were observed in the majority of tests when utilising US assisted operation. In terms of surface quality, SEM micrographs revealed greater side flow/ploughing and overlapping grit marks in slots machined with the workpiece vibrated in comparison to standard creep feed ground specimens. Three dimensional topographic measurement of grinding wheel surface replicas indicated that US vibration led to an increase in the number of active cutting points on the wheel. © 2012 ThePublished Authors. by Published Elsevier BV.by Elsevier Selection B.V. and/or Selection peer-review and/or peer-review under responsibility under responsibility of Prof. Konrad of Professor Wegener Konrad Wegener Keywords: Grinding; nickel; ultrasonics; vibration. 1. Introduction metal cutting (turning, drilling, milling & grinding) as well as metal forming processes. The use of ultrasonic actuation as a method for Some of the earliest work relating to ultrasonic material removal was first proposed in a paper by R.W. assisted grinding (UAG) dates back to the mid-1950’s Wood and A.L. Loomis in 1927, with the first patent [2] and highlighted benefits such as reductions in granted to L. Balamuth in 1945 [1]. Developments since grinding temperature and workpiece tensile residual then have seen ultrasonic machining (USM) applied to stresses, albeit at a cost of lower G-ratios due to a greater the cutting of hard but brittle materials such as glass, degree of wheel breakdown. Several years later, a ruby and ceramics. Traditional USM operation involves project undertaken by the United States Air Force a horn and tool arrangement vibrated at frequencies of reported work on excitation of the grinding wheel in a 20kHz with relatively small amplitudes of ~10-20μm, radial direction by attaching the transducer to a half- that is used to impact against an abrasive slurry between wave bar (the wheel hub) [3]. A novel technique the tool and workpiece causing localised fracture. The involving the use of US vibration to clean and prevent scope of the technology was further expanded to loading of pores in a grinding wheel was proposed by encompass ultrasonic vibration as an assistive Kaliszer and Limb [4], which utilised a special coolant mechanism in a ‘hybrid’ configuration with conventional activator oscillating along its axis and radial to the wheel 2212-8271 © 2012 The Authors. Published by Elsevier B.V. Selection and/or peer-review under responsibility of Professor Konrad Wegener http://dx.doi.org/ 10.1016/j.procir.2012.04.064 360 D. Bhaduri et al. / Procedia CIRP 1 ( 2012 ) 359 – 364 periphery. The ultrasonically cleaned wheels exhibited (~30-50%) were obtained when applying ultrasonic greater permeability, higher G-ratio and reduced chatter actuation, which also decreased thermal damage/ vibrations in comparison to the non-ultrasonically grinding burn, thereby improving workpiece surface treated wheels. finish. The majority of published work on UAG over the The body of research on UAG to date has mainly past ~20 years can be broadly divided into two sub- focussed on the surface grinding configuration of categories, depending on whether the vibration was materials such as ceramics, glass and various grades of applied to the grinding wheel or workpiece. Nakagawa steel (stainless, plain carbon, alloyed etc.), but little et al. [5] studied the effects of vibrating a cast iron fibre information is available on ultrasonic assisted grinding bonded diamond wheel during the grinding of alumina, of advanced aerospace materials such as nickel based silicon nitride and tungsten carbide. They found that superalloys. The aim of the current work was to larger depths of cut were possible leading to higher investigate the effect on grinding forces (vertical and material removal rates (MRR) and improved horizontal), workpiece surface roughness/quality (2D dimensional accuracy, together with a 60-70% reduction and 3D topographical parameters) and wheel wear (G- in normal grinding force. A similar system was also ratio), when employing ultrasonic vibration during creep shown to be capable of fabricating precision micro feed grinding (CFG) of Inconel 718 with an alumina cylindrical tools and micro drills [6], as well as wheel. producing machined features having non-circular cavities and blind holes with sharp corners [7]. While 2. Experimental details not generally recommended for ferrous alloys, Hara et al. [8] demonstrated that it was possible to produce The experimental trials were conducted on a mirror surfaces when grinding die steel (NAK80) with Bridgeport FGC1000 flexible grinding centre, with a diamond electroplated tools vibrating at a frequency of maximum spindle speed of 6000rpm and power rating of 60kHz and an amplitude of 4μm. Use of a vibrating 25kW. Rectangular blocks of solution treated and aged CBN wheel for grinding small holes in stainless steel Inconel 718 (hardness of ~44±1HRC) measuring was also found to reduce both normal and tangential 110×50×10mm were used as the workpiece material. forces as well as workpiece surface roughness by ~20% These were clamped onto a specially designed [9]. aluminium table/block sonotrode (similar to the one Research involving vibration of the workpiece has detailed by Azarhoushang and Tawakoli [19]) mounted been more extensive, primarily due to the comparatively on the machine worktable, which was connected to a simpler experimental setup. Spur and Holl [10] utilised a 1kW piezoelectric transducer-generator system, see Fig. workpiece based US assisted creep feed grinding system 1. The transducer was attached to transmit the US to achieve a 50% reduction in normal force when vibration in a direction parallel to grinding feed. The machining sintered silicon nitride and alumina, but at the alumina grinding wheels known commercially as expense of a marginal increase in wheel wear due to POROS 2, had a plain geometry, vitrified bond, open higher amounts of micro-splintering of grits under the structure (specification: 25A601 I 74 VPMCNN), a hybrid configuration. A similar wear mechanism was diameter of 220mm and a width of 25mm. observed by Uhlmann [11], whose study also revealed The full factorial experimental array comprised 18 that vibration rendered an intermittent cutting action tests involving variations in wheel speed (30, 35 and 40 together with higher mechanical but lower thermal loads m/s), table speed (200, 250 and 300 mm/min) and on the grits.
Load more

Recommended publications
  • Ceramic Machining: Assessment of Current Practice and Research Needs in the United States
    United States Department of Commerce Technology Administration National Institute of Standards and Technology NAT'L INST. OF STAND & TECH R,LC. NIST Special Publication 834 ~ NiST REFERENCE PUBLICATIONS Ceramic Macnimng: Assessment of Current Practice and Research Needs in the United States 7he National Institute of Standards and Technology was established in 1988 by Congress to "assist industry in the development of technology . needed to improve product quality, to modernize manufacturing processes, to ensure product reliability . and to facilitate rapid commercialization ... of products based on new scientific discoveries." NIST, originally founded as the National Bureau of Standards in 1901, works to strengthen U.S. industry's competitiveness; advance science and engineering; and improve public health, safety, and the environment. One of the agency's basic functions is to develop, maintain, and retain custody of the national standards of measurement, and provide the means and methods for comparing standards used in science, engineering, manufacturing, commerce, industry, and education with the standards adopted or recognized by the Federal Government. As an agency of the U.S. Commerce Department's Technology Administration, NIST conducts basic and applied research in the physical sciences and engineering and performs related services. The Institute does generic and precompetitive work on new and advanced technologies. NIST's research facilities are located at Gaithersburg, MD 20899, and at Boulder, CO 80303. Major technical operating
    [Show full text]
  • Investigating the Effect of Cryo Treated Tool and Work Material in Ultrasonic Machining of Titanium Alloys
    INVESTIGATING THE EFFECT OF CRYO TREATED TOOL AND WORK MATERIAL IN ULTRASONIC MACHINING OF TITANIUM ALLOYS. A THESIS Submitted in fulfillment of the requirements for the award of the degree of DOCTOR OF PHILOSOPHY in MECHANICAL ENGINEERING By GAURAV KUMAR DHURIA Registration. No. 950808008 THAPAR INSTITUTE OF ENGINEERING & TECHNOLOGY (Deemed to be University) PATIALA-147004, INDIA i PREFACE This research work was carried out by the author under the guidance of Dr. Ajay Batish, Professor, Department of Mechanical Engineering, Thapar University, Patiala and Dr. Rupinder Singh, Professor, Department of Production Engineering, Guru Nanak Dev Engineering College, Ludhiana. The experimentation for the presented work was carried out on Ti-6Al-4V titanium alloy to explore the effect of six process parameters on machining response variables such as material removal rate, tool wear rate, surface roughness and dimensional accuracy. Sonic Mill 500W Ultrasonic Machine Tool available in the Mechanical Engineering Department at Thapar University, Patiala was used for experimentation. Following articles have been published from the presented work: 1. Gaurav Kumar Dhuria, Rupinder Singh, Ajay Batish (2016) Predictive modeling of surface roughness in ultrasonic machining of cryogenic treated Ti-6Al-4V. Engineering Computations, 33 (8) 2377 – 2394 (SCIE - Impact Factor 0.691). 2. Gaurav Kumar Dhuria, Rupinder Singh, Ajay Batish,(2016) Application of a hybrid Taguchi-entropy weight-based GRA method to optimize and neural network approach to predict the machining responses in ultrasonic machining of Ti–6Al–4V. J Braz. Soc. Mech. Sci. Eng., 39 (7) 2619-2634 (SCIE – Impact Factor 0.963). 3. Rupinder Singh, Gaurav Kumar Dhuria, Ajay Batish (2017) Effect of Cryogenic Treatment on Ultrasonic Machining of Titanium and Its Alloys: A Review, Reference Module in Materials Science and Materials Engineering, http://dx.doi.org/10.1016/B978-0-12-803581-8.04157-6.
    [Show full text]
  • Precision in Machining: Research Challenges
    NISTIR 5628 Precision in Machining: Research Challenges Hans A. Soons Simone L. Yaniv U.S. DEPARTMENT OF COMMERCE Technology Administration National Institute of Standards and Technology Manufacturing Engineering Laboratory Automated Production Technology Division Gaithersburg, MD 20899 QC i°o NIST . U56 NO. 5628 1995 NISTIR 5628 Precision in Machining: Research Challenges Hans A. Soons Simone L. Yaniv U.S. DEPARTMENT OF COMMERCE Technology Administration National Institute of Standards and Technology Manufacturing Engineering Laboratory Automated Production Technology Division Gaithersburg, MD 20899 May 1995 U.S. DEPARTMENT OF COMMERCE Ronald H. Brown, Secretary TECHNOLOGY ADMINISTRATION Mary L. Good, Under Secretary for Technology NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY Arati Prabhakar, Director Acknowledgments We would like to thank all the participants in the workshop on Precision Machining, held October 12, 1994, in Gaithersburg, MD, for their invaluable contributions during the round table discussions. Special thanks go to Ray McClure and Chi-Hung Shen for agreeing to present key addresses, and for sharing their invaluable insights into research needs in the field of machining and precision. We would like also to express our thanks to Don Blomquist and Alkan Donmez for their support and encouragement during the preparation of this document. Special thanks go to Jerry Halley for agreeing to serve as the workshop rapporteur. i 0 Executive Summary This report looks at critical research needs for leading-edge technology developments in machining and precision that are important to the competitiveness and economic growth of the U.S. discrete-part industry. This industry produces individual products such as aircraft, automobiles, industrial machinery, home appliances, electric equipment, and all the individual components of which they are made.
    [Show full text]
  • Rotary Ultrasonic Machining of Hard-To-Machine Materials
    View metadata, citation and similar papers at core.ac.uk brought to you by CORE provided by K-State Research Exchange ROTARY ULTRASONIC MACHINING OF HARD-TO-MACHINE MATERIALS by NIKHIL CHURI B. S., University of Mumbai, India, 2002 ____________________________________________________ AN ABSTRACT OF A DISSERTATION Submitted in partial fulfillment of the requirements for the degree DOCTOR OF PHILOSOPHY Department of Industrial and Manufacturing Systems Engineering College of Engineering KANSAS STATE UNIVERSITY Manhattan, Kansas 2010 1 ABSTRACT Titanium alloy is one of the most important materials used in major segments of industries such as aerospace, automobile, sporting goods, medical and chemical. Market survey has stated that the titanium shipment in the USA has increased significantly in last two decades, indicating its increased usage. Industries are always under tremendous pressure to meet the ever-increasing demand to lower cost and improve quality of the products manufactured from titanium alloy. Similar to titanium alloys, silicon carbide and dental ceramics are two important materials used in many applications. Rotary ultrasonic machining (RUM) is a non-traditional machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining. It comprises of a tool mounted on a rotary spindle attached to a piezo-electric transducer to produce the rotary and ultrasonic motion. No study has been reported on RUM of titanium alloy, silicon carbide and dental ceramics. The goal of this research was to provide new knowledge of machining these hard-to- machine materials with RUM for further improvements in the machining cost and surface quality. A thorough research has been conducted based on the feasibility study, effects of tool variables, effects of machining variables and wheel wear mechanisms while RUM of titanium alloy.
    [Show full text]
  • Ultrasonic Machining (USM), 3
    KNOWLEDGE INSTITUTE OF TECHNOLOGY DEPARTMENT OF MECHANICAL ENGINEERING UNCONVENTIONAL MACHINING PROCESS UNIT I - INTRODUCTION Unconventional Machining Process – Need – Classification & Brief overview. MECH-KIOT Machining Processes Machining Processes Conventional Abrasive Nontraditional Turning Drilling Milling Other Grinding Lapping Mechanical Energy Polishing Other Electrochemical Thermal Energy Chemical Machining MECH-KIOT To reduce machining costs • Avoid excess machining allowances during primary processing • Achieve rough shape as “near net” as possible eg. Die casting a piston instead of sand casting reduces machining • Optimize initial shaping and final machining regarding the aspects like machine tools, cutting tools and cutting parameters MECH-KIOT Single – Point Tools Surface of revolution Plane (Job Surfaces rotating) Tool Feed parallel to axis Feed not parallel Job reciprocates reciprocates of rotation to axis of rotation shaping slotting (Cylindrical planing surfaces) External Internal turning, boring screw internal cutting screw cutting At any angle Simultaneous (Conical two axes motion surfaces) contouring, copy turning External taper Internal turning, Taper facing boring MECH-KIOT Multi – Point Tools Cylindrical Surface Plane Surfaces Two edge Multi edge Sizeable Chips Small Chips (Grinding) Surface Cutting cutting (Milling) Plane milling Broaching grinding Lapping drilling Gear shaping Sizeable Chips (Milling, Gear Small Chips cutting) Spiral milling (Grinding) Gear hobbing Cylindrical grinding Centre less grinding MECH-KIOT
    [Show full text]