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Ultrasonic-Assisted Dry Creep-Feed Up-Grinding of Superalloy Inconel738LC

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Abstract

Among many machining methods, grinding is the most applicable one for cutting hard-to-cut materials such as superalloys. In this research, effects of longitudinal ultrasonic vibration of workpiece (Inconel738LC) in dry creep-feed up-grinding process were investigated. Mechanism of abrasive grain and workpiece surface interaction and the consequences have been analyzed both analytically and numerically. Then, the results have been compared with experimental findings. Analytical calculations showed that there is a multiple and discontinuous cutting along the contact zone of grinding wheel and the workpiece when longitudinal ultrasonic vibration is used. Two-dimensional finite element modeling in commercial MSC.Superform software, showed the same behavior and results. Grinding forces are one of the major output parameters for evaluations. It was observed that, application of ultrasonic vibration can decrease grinding forces. A practical decrease of up to 27% of vertical grinding forces and up to 22% of horizontal grinding forces has been achieved when using ultrasonic vibration. Finite-Element analysis has shown a reduction of about 40% of grinding forces compared with ordinary grinding. Probable lower risks of thermal damage even for working under dry conditions can be a big advantage of using ultrasonic with grinding.

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Abbreviations

symbol (unit):

definition

r (mm):

Grinding wheel radius

a (μm):

Depth of cut

l c (mm):

Grinding wheel and workpiece contact length

\( {l_c}\prime \) (mm):

Grinding wheel and workpiece approximated contact length

α (rad):

Central angle of grinding wheel and workpiece contact arc

\( \alpha \prime \) (rad):

Slope angle of approximated contact length

v s (m/s):

Grinding wheel peripheral velocity

v sx (m/s):

Cutting grain horizontal velocity

v sy (m/s):

Cutting grain vertical velocity

v w (mm/min):

Workpiece feed speed

v f (mm/s):

Cutting grain feed speed

v us (mm/s):

Ultrasonic vibration speed

v x,grain (mm/s):

Cutting grain horizontal relative speed

v y,grain (mm/s):

Cutting grain vertical relative speed

u x,grain (mm):

Cutting grain horizontal relative displacement

u y,grain (mm):

Cutting grain vertical relative displacement

u us (μm):

Ultrasonic vibration displacement

\( \omega \prime \) (rad/s):

Grinding wheel angular speed

ω (rad/s):

Vibration angular frequency

f (kHz):

Vibration frequency

u max (μm):

Vibration amplitude

t (s):

Time

\( t\prime \) (s):

Cutting grain displacement time along cutting arc

F x (N):

Horizontal grinding force

F y (N):

Vertical grinding force

θ OG (rad):

Penetration angle of a grain into workpiece in ordinary grinding

θ UAG,in (rad):

Penetration angle of a grain into workpiece in ultrasonic assisted grinding

θ UAG,out (rad):

Exit angle of a grain from workpiece in ultrasonic assisted grinding

μ (-):

Friction coefficient

υ (-):

Poisson ratio

ρ (gr/cm 3):

density

E (GPa):

Elasticity modulus

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Authors and Affiliations

  1. Mechanical Engineering, Amirkabir University of Technology, No. 424, Hafez Ave., P.O. Box: 15875–4413, Tehran, Iran

    A. Abdullah

  2. Manufacturing Engineering, Department of Mechanical Engineering, Isfahan University of Technology, Isfahan, Iran

    A. Farhadi

  3. Mechanical Engineering, Iran University of Science and Technology (Arak Branch), Arak, Iran

    A. Pak

Authors
  1. A. Abdullah
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  2. A. Farhadi
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  3. A. Pak
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Corresponding author

Correspondence to A. Abdullah.

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Abdullah, A., Farhadi, A. & Pak, A. Ultrasonic-Assisted Dry Creep-Feed Up-Grinding of Superalloy Inconel738LC. Exp Mech 52, 843–853 (2012). https://doi.org/10.1007/s11340-011-9557-1

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  • DOI: https://doi.org/10.1007/s11340-011-9557-1

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