Abstract
The grinding process is often maligned by grinding burn; which refers to many unwanted effects, including residual stress formation. This paper presents an overview of the role of grinding wheel technologies in the surface response and residual stress formation of thin section Inconel 718. Using production standard equipment, conventional abrasive vitrified, and super abrasive electroplated wheel technologies were evaluated in initial comparative trials. Results revealed the dominant residual stress profiles, which manifested as measurable distortion and the thermo-mechanical impact of grinding, such as softening. Following this, a parametric study was carried out using cubic boron nitride super abrasive electroplated wheels to investigate the interaction of grinding parameters on the generated output. It was shown that at increased grinding aggressions, tensile stress regimes increased resulting in increased distortion magnitudes. The study highlights the importance of assessing residual stress formation when manipulating both wheel technologies and grinding parameters. It is envisaged that with additional assessment, a route to an engineered residual stress profile might be achieved.
Highlights
Grinding processes are prevalent in the manufacture of aero engine components for high temperature applications where tolerances and features demand such processes.[1]
This paper aims to provide an overview of the residual stress and surface integrity response of Inconel 718 to grinding wheel technologies
Literature frequently reports residual stress formation being a function of grinding temperature, the two abrasives have produced significant differences in stress formation. This suggests that the balance between thermal and mechanical interaction, which is driven by grinding wheel thermal conductivity and resulting energy partition as well as the mechanics of material removal, drive residual stress states without necessarily manifesting themselves as surface integrity defects
Summary
Grinding processes are prevalent in the manufacture of aero engine components for high temperature applications where tolerances and features demand such processes.[1]. The residual stress response when grinding with cBN wheels, was evaluated further as it has been reported that they are preferred for grinding applications where thermal damage of the work piece is a problem.[7] Within literature, there is a gap in trying to relate key process variables to specific output metrics such as residual stress profile generation and the resulting impact on workpiece distortion.
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