Abstract
Creep feed grinding is a recently invented process of material handling. It combines high quality of the piece surface, productivity, and the possibility of automatic control. The main objectives of this research is to study the influences of major process parameters and their interactions of creep feed grinding process such as wheel speed, workpiece speed, grinding depth, and dresser speed on the pin gauge dimensions of root of gas turbine blade by design of experiments (DOE). Experimental results are analyzed by analysis of variance (ANOVA) and empirical models of pin gauge dimensions of root are developed. The study found that higher wheel speed along with slower workpiece speed, lower grinding depth and higher dresser speed, cause to obtain best conditions for pin gauge dimensions of root.
Highlights
Grinding has traditionally been associated with small rates of material removal and fine finishing operations
The main objectives of this research is to study the influences of major process parameters and their interactions of creep feed grinding process such as wheel speed, workpiece speed, grinding depth, and dresser speed on the pin gauge dimensions of root of gas turbine blade by design of experiments (DOE)
The results show that an increase of dresser speed combined with the increase of grinding depth, produces small absolute value of difference between the measured dimensions and nominal dimension of pin gauge dimension
Summary
Grinding has traditionally been associated with small rates of material removal and fine finishing operations. Using an approach known as creep-feed grinding (Figure 1), a large-scale metal removal similar to milling can be achieved Using this approach, higher material removal rates can be performed by selection of a higher depth of cut and lower workpiece speed. One of the most important applications of creep-feed grinding is the production of the aerospace parts used in jet engines such as turbine vanes, and blades where parts should have high strength to the fatigue loads and creep strains. These parts are made from nickel-based super-alloys such as Inconel, Udimet, Rene, Waspaloy, and Hastelloy. They provide a higher strength to weight ratio, and maintain high resistance to corrosion, mechanical thermal fatigue, and mechanical and thermal shocks [1]
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