Abstract
Component edge profiling is a novel, complex, labor intensive process that is performed on highly stressed features on aerospace parts such as turbine rotor discs employed in aero-engines. This paper is the first of its kind in this area of research. A novel experimental investigation carried out on surface integrity of Inconel 718 during automated abrasive edge profiling process is presented. Edge profiling tests were conducted using compliant Flexhone™ and Novoflex™globular abrasives on turbine bolt and flange holes to the required aerospace part drawing standard. According to the developed globular brush selection criterion, for a given hole size and edge profile geometry and size, the key process variables that impacted the component life were identified. Nylon impregnated silicon carbide globular brushes (320 grit size) showed a satisfactory abrasive performance between cutting and polishing action on tough class 5 extruded burrs. The optimized abrasive edge profiling parameters were used to manufacture 34 center hole specimens which were tested under low cycle fatigue conditions to confirm the ability of abrasive edge profiling process. Fatigue test results demonstrated that automated abrasive edge profiling does not cause fatigue life deficit compared to manual dressing. Both 2-body and 3-body wear mechanisms were observed. Higher the brushed surface Rv (deepest valley on brushed surface profile), lower the fatigue life of the part.
Published Version
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