Abstract
The nickel-based superalloy GH3128 with high plasticity, high long-lasting creep strength, good resistance to oxidation and stamping, and good welding performance is widely used in aircraft engine heat shields. The many holes that need to be machined on the heat shield are not only small in diameter but also dense, and GH3128 as a typical hard-to-process material has the problems of large cutting force, high cutting temperature, and serious hardening. Therefore, poor dimensional accuracy and residual burrs have become the main factors that limit the processing efficiency and processing quality. So, a novel combination of manufacturing processes was proposed. Firstly, laser cutting technology was used to process the base hole in a GH3128 plate, followed by reaming, and finally, using a magnetic abrasive finishing effector to remove burrs formed during the first two steps. The whole drilling process of the heat shields fully meets the requirements of the technical parameters. This study provides new reference for manufacturing the holes of a heat shield and other similar porous parts.
Highlights
GH3128 is a nickel-based superalloy with a solid solution of tungsten and molybdenum and is reinforced with boron, niobium, and zirconium
The conclusion of the analysis of variance (ANOVA) was consistent with the result obtained in Table 4 in the intuitive analysis, which further proves the correctness of the intuitive analysis
Aiming at the heat shield of an aeroengine, a composite holemanufacturing technology is proposed based on a laser cutting process, a reaming process, and the MAF process
Summary
GH3128 is a nickel-based superalloy with a solid solution of tungsten and molybdenum and is reinforced with boron, niobium, and zirconium. Due to the small diameter and the higher position accuracy of these holes, it is difficult to create them using the traditional punching or drilling process in this thin-walled surface. Precision punching, electrical discharge machining (EDM), or laser cutting technology was used for manufacturing thin-walled holes. Ko et al in 2003 [6] claimed that the step drill performs front edge cutting before step edge cutting, and the burr formed during the first cutting can be removed during the second cutting by step edge These conventional processing schemes generally suffer from problems such as expensive manufacturing cost, poor versatility, poor hole-positioning accuracy, microcracks on the wall of the hole, or low processing efficiency. Because of large size and complex shape of the heat shield, it is difficult to manufacture the hole and meet all of technical requirements using a conventional drilling process. The novel process was proposed for achieving the goal of making qualified holes in a heat shield
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