IC10定向凝固高温合金缓进磨削工艺参数优化研究

通过设计正交试验,研究了IC10高温合金在缓进磨削过程中磨削工艺参数及表面粗糙度对疲劳寿命的影响规律,建立了工艺参数对磨削表面粗糙度及疲劳寿命影响的映射关系模型,并以表面粗糙度、疲劳寿命、材料去除率为优化目标进行了IC10高温合金缓进磨削工艺参数多目标优化.研究表明,IC10高温合金磨削工件疲劳寿命随砂轮线速度的增加而...     

加工表面粗糙度及其对GH4169高温合金疲劳寿命的影响

借助扫描电子显微镜观察和分析了用刚玉砂轮磨削ＧＨ４１６９高温合金的磨削表面形貌。通过试验，研究了ＧＨ４１６９高温合金表面粗糙度与加工参数间的关系；根据正交试验建立了磨削表面粗糙度的经验公式；分析了加工表面粗糙度对ＧＨ４１６９高温合金疲劳寿命的影响规律。     

DZ125材料涡轮叶片榫齿磨削

叙述ＤＺ１２５高温合金定向铸造涡轮叶片齿磨削工艺试验及参数的确定。     

电镀CBN砂轮缓进给磨削高温合金叶片窄深槽的试验研究

介绍了ＣＢＮ 砂轮缓进给磨削高温合金的磨削性能及电镀ＣＢＮ砂轮的磨削特点；针对发动机涡轮叶片根部窄深槽的加工难题，研究了电镀ＣＢＮ砂轮的制作和修整方法，并进行了电镀ＣＢＮ砂轮缓进给磨削高温合金叶片窄深槽的加工试验     

镍基高温合金高效成型磨削的研究进展与展望

镍基高温合金因其优异的高温强度、热稳定性和抗疲劳特性,被广泛应用于航空发动机的核心部件,该材料机械加工性差,成型加工更加困难。本文阐述了镍基高温合金高效磨削工艺的研究现状,找出了成型磨削加工应用中存在的瓶颈,并对现有的解决方法加以剖析;提出以确保成型面具有相同单颗磨料切厚为目标优化成型砂轮磨粒排布,并与高效深切磨削工艺(HEDG)相结合的构想,以达到进一步挖掘高效成型磨削技术在航空难加工材料成型加工中潜力之目的。     

超硬砂轮磨削高温合金粘附修锐技术研究

针对高温合金超硬砂轮磨削粘附的特点,将高温合金磨削粘附分为轻度粘附、中度粘附、重度粘附、粘连粘附等几种形式,通过分析磨屑生成机理,解释了磨削粘附原因。验证了超硬砂轮新型磨削修锐方法的可行性。避免了在磨粒切削能力没有损失情况下,只因为粘附物附着的原因无法使用的情况,大幅提升超硬砂轮使用寿命。     

DZ4材料的磨削烧伤机理

通过磨削温度、磨削力测量等基本试验研究了DZ4镍基高温合金的磨削烧伤现象,并通过金相检验揭示了它的磨削烧伤机理.研究结果表明,这种材料在磨削温度超过800?℃时即发生烧伤,而磨削力比可作为特征参量对磨削烧伤进行监测和预报.     

DZ4材料的磨削烧伤机理

通过磨削温度、磨削力测量等基本试验研究了DZ4镍基高温合金的磨削烧伤现象 ,并通过金相检验揭示了它的磨削烧伤机理。研究结果表明 ,这种材料在磨削温度超过 80 0℃时即发生烧伤 ,而磨削力比可作为特征参量对磨削烧伤进行监测和预报。     

DD5镍基单晶高温合金缓进磨削力和温度实验研究

涡轮叶片榫齿缓进磨削过程热力载荷效应对成型表面质量具有重要影响。基于实验研究磨削参数对DD5 单晶高温合金磨削力和温度的影响规律,分析缓进磨削力和温度形成机理,构建 DD5 缓进磨削力、温度与磨削工艺参数的映射模型并进行验证。结果表明：DD5 缓进磨削深度对磨削力和磨削温度的影响最为显著,砂轮线速度次之,工件进给速度对其影响最小;随着砂轮线速度的增大,磨削力降低、磨削温度升高;随着工件进给速度和磨削深度的增大,磨削力和磨削温度均呈升高趋势;满足材料去除速率的前提下提高工件进给速度并降低磨削深度,可以避免 DD5 磨削表面出现较大的磨削热力耦合影响层。     

机器人自适应砂带磨削镍基高温合金精铸叶片试验研究

镍基高温合金精铸叶片由于其铸造余量大、定位无基准等,在加工时难以保证其加工精度。采用机器人砂带磨削方式并结合自适应加工技术,对镍基高温合金航空发动机精铸叶片进行磨削。通过对精铸叶片采用三坐标6点迭代的方式,确定航发叶片相对于夹具的位置;然后进行轨迹规划并提取点位信息,建立四阶齐次矩阵反求出机器人运动轨迹,保证磨削位姿和磨削参数;最后根据叶片型面余量信息,采用自适应加工方法,对航发精铸叶片进行定量的材料去除,保证其加工精度。     

K417航空叶片材料缓进深磨烧伤特征及烧伤程度判别

 利用扫描电镜、电子探针、x射线光电子谱仪等测试分析手段,按照传统的烧伤分档标准对K417铸造镍基高温合金缓进磨削时烧伤表面的形成机理及烧伤表面层物理性态所发生的种种变化进行了系统的研究。文中针对高温合金本身的特点,结合性态测试与疲劳试验结果指出:仅有紫色档才可能对零件的使用寿命构成实质性损伤。     

Vibration coupling effects and machining behavior of ultrasonic vibration plate device for creep-feed grinding of Inconel 718 nickel-based superalloy

Ultrasonic vibration-assisted grinding(UVAG) is an effective and promising method for machining of hard-to-cut materials. This article proposed an ultrasonic vibration plate device enabling the longitudinal full-wave and transverse half-wave(L2T1) vibration mode for UVAG.The characteristics of two-dimensional coupled vibration in different directions were analyzed on the basis of apparent elastic method and finite element method. Furthermore, a correction factor was applied to correct the freque...     

断续 CBN 砂轮缓进给磨削 K417 航空叶片材料的研究

 全面比较了用Al2O3和CBN磨削K417铸造高温合金时的磨削效果，指出：Al2O3不适于高效磨削K417之类的航空难加工材料，而CBN是实现该材料高效深切磨削的有效工具。通过大量实验，验证了断续CBN砂轮缓进给磨削K417时的技术优势，解决了树脂结合剂应用于断续磨削时所遇到的新问题。分析显示出该技术具有很好的应用前景和极大的推广价值。     

Effect of creep feed grinding on surface integrity and fatigue life of Ni3Al based superalloy IC10

Ni₃Al-based superalloy IC10 is widely used in high temperature components of aero-engines because of its superior mechanical properties. In this paper, the creep feed grinding properties of IC10 were investigated experimentally. The effects of grinding parameters on the grinding forces and temperature were examined. Moreover, the influences of surface roughness and hardening on the high-cycle fatigue life of IC10 specimens were studied. To control the creep feed grinding parameters and enhance the fatigue life of IC10 components, the experimental results were summarized to offer a useful reference point. It is concluded that, the grinding depth is the most important factor which influencing the grinding forces and temperature; the surface roughness is the main and unfavorable factor on the fatigue life of IC10, while the surface hardening has a positive influence on the fatigue life; to obtain a better surface quality and improve the fatigue life of IC 10, the recommended grinding parameter domain involves wheel speed ∈ [15, 20] m/s, feed rate ∈ [150, 200] mm/min, and grinding depth ∈ [0.4, 0.5] mm.     

Grinding force and surface quality in creep feed profile grinding of turbine blade root of nickel-based superalloy with microcrystalline alumina abrasive wheels

Creep feed profile grinding of the fir-tree blade root forms of single crystal nickel-based superalloy was conducted using microcrystalline alumina abrasive wheels in the present study. The grinding force and the surface quality in terms of surface topography, subsurface microstructure, microhardness and residual stress obtained under different grinding conditions were evaluated comparatively. Experimental results indicated that the grinding force was influenced significantly by the competing predominance between the grinding parameters and the cross-sectional root workpiece profile. In addition, the root workpiece surface, including the root peak and valley regions, was produced with the large difference in surface quality due to the nonuniform grinding loads along the root workpiece profile in normal section. Detailed results showed that the surface roughness, subsurface plastic deformation and work hardening level of the root valley region were higher by up to 25%, 20% and 7% in average than those obtained in the root peak region, respectively, in the current investigation. Finally, the superior parameters were recommended in the creep feed profile grinding of the fir-tree blade root forms. This study is helpful to provide industry guidance to optimize the machining process for the high-valued parts with complicated profiles.     

GH4169DA磨削表面变质层软化机理

为了深入研究高温合金GH4169DA磨削表面变质层软化机理,分别采用光学显微镜、显微维氏硬度计和透射电子显微镜（TEM）分析了其微观组织、显微硬度和γ"相密度。试验结果表明：GH4169DA磨削表面及亚表面发生了明显软化和局部塑性变形。在试验参数范围内,软化深度约为30~100 μm,而变形层的深度只有约4 μm。从基体到磨削表面,γ"相密度由约2.27×10³个/μm²逐渐降低,至距磨削表面约2.2 μm以内γ"相完全消失。该变化规律与显微硬度变化规律一致,最大影响深度也基本相同。分析指出,GH4169DA磨削表面软化的根本原因是在磨削过程中热的作用下,主要强化相γ"密度降低,强化效果减弱。     

Fretting wear behaviour of machined layer of nickel-based superalloy produced by creep-feed profile grinding

Fretting wear has an adverse impact on the fatigue life of turbine blade roots. The current work is to comparatively investigate the fretting wear behaviour of the nickel-based superalloy surfaces produced by polishing and creep-feed profile grinding, respectively, in terms of surface/subsurface fretting damage, the friction coefficient, wear volume and wear rate. Experimental results show that the granulated tribolayer aggravates the workpiece wear, while the flat compacted tribolayer enhances the wear resistance ability of workpiece, irrespective of whether the workpiece is processed by polishing or grinding. However, the wear behaviors of tribolayers are different. For the polished surface, when the normal load exceeds 100 N, the main defects are crack, rupture, delamination and peeling of workpiece materials; the wear mechanism changes from severe oxidative wear to fatigue wear and abrasive wear when the loads increase from 50 to 180 N. As for the ground surface, the main wear mechanism is abrasive wear. Particularly, the ground surface possesses better wear-resistant ability than the polished surface because the former has the lower values in coefficient friction (0.23), wear volume (0.06 × 10⁶ μm³) and wear rate (0.25 × 10^?16 Pa^?1). Finally, an illustration is given to characterize the evolution of wear debris on such nickel-based superalloy on the ground surface.     

磁流变弹性体砂轮抛光镍基高温合金表面完整性研究

为了改善磨削后镍基高温合金GH4169的表面完整性,本文采用磁流变弹性体砂轮对镍基高温合金GH4169进行抛光试验研究。首先,通过模压成型的方法制备了磁流变弹性体砂轮,并对其表面微观形貌及不同磁场强度下的硬度进行了表征。其次将制备出的磁流变弹性体砂轮用于对镍基高温合金GH4169的抛光工艺试验中,并讨论抛光工艺参数中磁场强度对镍基高温合金表面完整性的影响。试验结果表明：在一定的磁场强度范围内,零件抛光后的表面粗糙度和显微硬度随着磁场强度的增大而减小,同时增大磁场强度也有利于改善零件的表面形貌,减少砂轮的磨损量,降低零件磨削后的亚表面损伤层厚度。     

TC4钛合金高效磨削加工用环形热管砂轮的研制

针对航空航天高强韧性难加工材料TC4钛合金在磨削加工中存在磨削温度高而导致工件表面烧伤的问题,提出利用热管换热技术冷却磨削弧区的新方法.分析了环形热管砂轮在加工中对磨削弧区的强化换热原理,并设计制作出能够用于磨削加工的环形热管砂轮,同时实现了对砂轮基体内环形管腔的密封、抽真空、精确注液与机械式真空封口.最后,在相同磨削工艺条件下,使用环形热管砂轮和无热管砂轮进行TC4钛合金缓进给深切磨削对比试验,验证了环形热管砂轮对磨削弧区温度的控制效果.试验结果表明:设计制作的环形热管砂轮在TC4钛合金高效磨削过程中可以有效降低磨削温度,避免工件表面出现烧伤.     

Al2O3陶瓷蠕动进给超声磨削加工表面质量的试验研究

为探索利用简单形状砂轮对陶瓷材料进行数控展成型面超声磨削,通过对Al2O3陶瓷进行蠕动进给超声磨削和机械磨削对比试验研究,探索各加工参数对磨削表面质量的影响规律.结果表明:超声振动方向与蠕动进给方向平行时可降低表面粗糙度值,而超声振动方向与蠕动进给方向垂直时则不利于改善加工表面质量;在超声磨削条件下,为了提高加工表面质量,应采取较小的磨削深度、较低的进给速度和适当高的磨削速度以及复合进给磨削方式.结合试验结果理论分析了蠕动进给超声磨削和蠕动进给机械磨削加工机理,并根据试验结果选择磨削参数进行了陶瓷叶片型面超声磨削的可行性试验.