Title: Chip formation of nickel-based superalloy in high speed grinding with single diamond grit

Authors: Zhenzhen Chen; Lin Tian; Yucan Fu; Jiuhua Xu; Wenfeng Ding; Honghua Su

Addresses: College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, 210016, China. ' College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, 210016, China. ' College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, 210016, China. ' College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, 210016, China. ' College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, 210016, China. ' College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, 210016, China

Abstract: In order to understand chip formation mechanism during high speed grinding of nickel-based superalloy, grinding tests with single brazed diamond grit were performed with the wheel speed from 20 m/s to 150 m/s. The kinematic grit trace was geometrically optimised to meet the requirement of the real grinding process. The maximum undeformed chip thickness was kept at 1 µm. Grooves and chips were observed and analysed by means of optical microscope and scanning electron microscope. The results obtained showed that, when the wheel speed was below 60 m/s, the serrated behaviour of the chips was not obvious. However, the typical serrated behaviour took place on the free surface in case of the wheel speed of above 60 m/s. The frequency of the chip segmentation was increased linearly with the increasing grinding speed from 60 m/s to 150 m/s.

Keywords: single grit grinding; high speed grinding; nickel based superalloys; brazed diamond grit; undeformed chip thickness; grooves; chip morphology; chip formation; high speed machining; grinding speed.

DOI: 10.1504/IJAT.2012.048537

International Journal of Abrasive Technology, 2012 Vol.5 No.2, pp.93 - 106

Received: 18 Nov 2011
Accepted: 29 Feb 2012
Published online: 30 Jul 2014 *

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