Grinding of Single-Crystal Superalloys

Comprehensive reference on state-of-the-art aerospace materials, reviewing the latest developments in the field and providing guidance on machining challenges

Grinding of Single-Crystal Superalloys provides a comprehensive understanding of grinding technology for single-crystal nickel-based superalloys. It explores and analyzes grinding mechanisms and characteristics using both theoretical and simulation approaches. Grinding behavior in conventional and micro grinding processes are evaluated and compared.

The book assesses the surface integrity of single-crystal nickel-based superalloys under different grinding conditions. Simulation and theoretical models for predicting temperature and residual stresses in profile grinding, facilitating optimization, and control are summarized and validated.

Grinding of Single-Crystal Superalloys discusses sample topics including:

• Friction coefficient, wear volume, and wear rate during fretting
• Influence of material anisotropy and different crystal orientations
• Residual stress fields in grinding of single-crystal turbine blade roots
• Yield and failure criterion
• Analysis of formation mechanisms in nanostructures

Grinding of Single-Crystal Superalloys is an essential reference for industry professionals and researchers seeking to understand the machining theory and practice of this important type of material, especially in the field of aerospace components manufacturing.

Contents

Foreword

Preface

Part I Grinding mechanism of single-crystal nickel alloy

Chapter 1 Introduction

1.1 Development and practical application of single-crystal nickel alloy

1.2 Advantages of grinding technology of single crystal nickel alloy

1.3 High-efficiency grinding technology development of single crystal nickel alloy

1.4 Micro-grinding technology development of single-crystal nickel alloy

1.5 Contents of this book

References

Chapter 2 Removal mechanism of single-crystal nickel alloy in high-efficiency grinding

2.1 Yield criterion and failure criterion of single-crystal nickel alloy

2.2 Simulation model and experiment conditions

2.3 Simulation results on material removal by multi abrasive grains

2.4 Experimental verification of simulation results

References

Chapter 3 Plastic deformation mechanism of single-crystal nickel alloy in micro-grinding

3.1 Verification of plastic deformation mechanism in micro-grinding materials

3.2 Microscale Debris in Micro - grinding of Single - crystal Nickel Alloy

Reference

Part II Grindability of single-crystal nickel alloys

Chapter 4 Grinding force evaluation

4.1 Grinding force in surface grinding

4.2 Grinding force in profile grinding

4.3 Grinding Force in Micro-grinding

Reference

Chapter 5 Grinding temperature evaluation

5.1 Grinding temperature in surface grinding

5.2 Grinding temperature in profile grinding

5.3 Grinding Temperature in Micro-grinding

Reference

Chapter 6 Grinding wheel wear evaluation

6.1 Grinding wheel wear in surface grinding

6.2 Grinding wheel wear in profile grinding

6.3 Grinding Wheel Wear in Micro-Grinding

Reference

Part III Surface integrity by high-efficiency grinding

Chapter 7 Surface and subsurface microstructures in high-efficiency grinding

7.1 Surface microstructure and surface roughness in surface grinding

7.2 Subsurface microstructure in surface grinding

7.3 Surface microstructure and surface roughness in profile grinding

7.4 Subsurface microstructure in profile grinding

Reference

Chapter 8 Subsurface nanostructures in high-efficiency grinding

8.1 Subsurface nanostructures in profile grinding

8.2 Analysis on formation mechanism of nanostructures

8.3 Plastic Deformation and microstructure evolution of single-crystal nickel superalloy

Reference

Chapter 9 Microhardness and residual stresses in high-efficiency grinding

9.1 Microhardness in surface grinding

9.2 Microhardness in profile grinding

9.3 Residual stresses in profile grinding

Reference

Chapter 10 Fretting wear behavior of the machined surface in high-efficiency grinding

10.1 Friction coefficient, wear volume and wear rate during fretting

10.2 Surface and subsurface microstructure during fretting

10.3 Analysis on fretting wear evolution of the ground surface

Reference

Part IV Surface integrity in micro-grinding

Chapter 11 Surface roughness in micro-grinding

11.1 Theoretical model of surface roughness

11.2 Influence of grinding parameters

11.3 Influence of material anisotropy of nickel-based single-crystal superalloy

11.4 Influence of different crystal orientations of nickel-based single-crystal superalloy

11.5 Influence of grinding methods

Reference

Chapter 12 Ground surface and subsurface damage in micro-grinding

12.1 Influence of grinding parameters

12.2 Influence of working fluid

Reference

Chapter 13 Subsurface microstructure and recrystallization in micro-grinding

13.1 Subsurface microstructure in the micro-grinding process

13.2 Subsurface recrystallization in micro-grinding

Reference

Part V Simulation, optimization and control in grinding of single-crystal turbine blade root

Chapter 14 Temperature field in grinding of single-crystal turbine blade root

14.1 FE model for grinding temperature simulation

14.2 Thermal analysis for grinding temperature simulation

14.3 Experimental validation of grinding temperature

14.4 Temperature simulation results and analysis

References

Chapter 15 Residual stress field in grinding of single-crystal turbine blade root

15.1 Mechanical analysis for residual stress simulation

15.2 Experimental verification of residual stresses

15.3 Residual stress simulation results and analysis

15.4 Collaborative manufacturing of structure shape and surface integrity

Reference

Prof. Wenfeng Ding dedicated his research in the field of advanced manufacturing theory and technologies.

Dr. Qing Miao dedicated his research in the field of advanced material microstructure characterization and high-quality and high-efficiency grinding technology of nickel-based superalloys.

Dr. Yao Sun researches basic theory and technology of the grinding process of difficult-to-machine materials, intelligent manufacturing, and micro-scale machining.

Ning Qian is an Associate Professor at Nanjing University of Aeronautics and Astronautics (NUAA).

Biao Zhao is an Associate Professor of Mechanical Engineering and Master's Tutor at Nanjing University of Aeronautics and Astronautics, China.

Prof. Jiuhua Xu teaches and researches the grinding of difficult-to-cut materials.