A study on ultrasonic assisted creep feed grinding of nickel based superalloys

Debajyoti Bhaduri, Sein Soo, David Aspinwall, Donka Novovic, Peter Harden, S. Bohr, D. Martin

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43 Citations (Scopus)
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Abstract

The paper initially reviews research relating to ultrasonic (US) assisted grinding of various workpiece materials. Results from
experimental trials to evaluate the influence of applying US vibration when creep feed grinding Inconel 718 with an open
structured, alumina based grinding wheel (POROS 2) are then presented. A full factorial experimental array comprising 18 runs
was conducted involving variation in wheel speed (30, 35 and 40m/s), table speed (200, 250 and 300mm/min) and grinding
condition (with and without vibration). For tests with US vibration, the workpiece was actuated at a constant frequency (~20kHz)
via a specially designed block sonotrode attached to a 1kW piezoelectric transducer-generator system. Reductions in vertical (FV)
and horizontal (FH) grinding force components of up to 23% and 43% for FV and FH respectively and surface roughness (Sa) of the
ground slots by up to 45% were observed in the majority of tests when utilising US assisted operation. In terms of surface quality,
SEM micrographs revealed greater side flow/ploughing and overlapping grit marks in slots machined with the workpiece vibrated
in comparison to standard creep feed ground specimens. Three dimensional topographic measurement of grinding wheel surface
replicas indicated that US vibration led to an increase in the number of active cutting points on the wheel.
Original languageEnglish
Pages (from-to)359-364
Number of pages6
JournalProcedia CIRP
Volume1
DOIs
Publication statusPublished - 2012

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