Abstract
The development of modern jet engines would not be possible without dynamically developed nickel–chromium-based superalloys, such as INCONEL® The effective abrasive machining of above materials brings with it many problems and challenges, such as intensive clogging of the grinding wheel active surface (GWAS). This extremely unfavorable effect causes a reduction in the cutting ability of the abrasive tool as well as increase to grinding forces and friction in the whole process. The authors of this work demonstrate that introduction of a synthetic organosilicon polymer-based impregnating substance to the GWAS can significantly improve the effects of carrying out the abrasive process of hard-to-cut materials. Experimental studies were carried out on a set of a silicon-treated small-sized sol–gel alumina 1-35×10×10-SG/F46G10VTO grinding wheels. The set contained abrasive tools after the internal cylindrical grinding process of INCONEL® alloy 600 rings and reference abrasive tools. The condition of the GWAS after the impregnation process was studied, including imaging and measurements of its microgeometry using confocal laser scanning microscopy (CLSM), microanalysis of its elemental distribution using energy dispersive X-ray fluorescence (EDXRF), and the influence of impregnation process on the grinding temperature using infrared thermography (IRT). The obtained results confirmed the correctness of introduction of the impregnating substance into the grinding wheel structure, and it was possible to obtain an abrasive tool with a recommended characteristic. The main favorable features of treated grinding wheel concerning the reduction of adhesion between the GWAS and grinding process products (limitation of the clogging phenomenon) as well as reduction of friction in the grinding process, which has a positive effect on the thermal conditions in the grinding zone.
Highlights
Among the many advanced materials used in today’s key branches of the aeronautical industry, the hard-to-cut austenitic nickel–chromium-based superalloys, described in detail by Reed et al [1] and Geddes et al [2], play the most important role
From the wide group of such materials the INCONEL® family superalloys are significant in terms of the varieties produced, which are characterized by different chemical composition, physical, mechanical, and thermal properties as well as wide range of applications, which was presented by Sharma et al [3], and Pashmforoush and Bagherinia et al [4]
Intensive clogging causes a reduction in the cutting ability of the grinding wheel active surface (GWAS), increase to grinding forces, and friction share in the whole process
Summary
Among the many advanced materials used in today’s key branches of the aeronautical industry, the hard-to-cut austenitic nickel–chromium-based superalloys, described in detail by Reed et al [1] and Geddes et al [2], play the most important role. Intensive clogging causes a reduction in the cutting ability of the grinding wheel active surface (GWAS), increase to grinding forces, and friction share in the whole process This is a strongly unfavorable effect which, in industrial practice, tries to reduce considerably by using various types of solutions tailored to the specificity of the given technological process. Searching for new impregnating substances, scientists drew attention to multi-molecular organosilicon compounds (organopolysiloxanes)—the silicones In these synthetic polymer materials, the siloxane skeleton is the main component of their structure. The Si–C binding is stable up to 500 ◦C (932 ◦F), but only in an anaerobic atmosphere The resistance of this bond to the oxidation process is much lower, the heat resistance of silicones in the presence of oxygen for siloxanes is about 200 ◦C (392 ◦F) as reported by Stevents et al [10]
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