Grinding force prediction and surface integrity analysis of Ti-4822 alloy formed by laser-directed energy deposition
Grinding force prediction and surface integrity analysis of Ti-4822 alloy formed by laser-directed energy deposition
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DOI：
10.1007/s00170-023-12255-7
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发表时间：
2023-09
期刊：
影响因子：
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通讯作者：
Dingkun Xu;Bo Xin;Xiaoqi Wang;Jiangyu Ren;Yadong Gong
中科院分区：
文献类型：
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作者：
Dingkun Xu;Bo Xin;Xiaoqi Wang;Jiangyu Ren;Yadong Gong
Ti-4822 TiAl合金是一种典型的金属间化合物，在航空和航天领域具有巨大的应用潜力，广泛应用于航空发动机高压压气机和低压涡轮机叶片。激光能量沉积（LDED）技术适合于钛4822合金复杂形状和结构的成形。然而，LDED Ti-4822合金是一种典型的硬脆和难加工材料，表面粗糙度和导热性差，导致磨削表面完整性差。为了研究和改善激光磨削Ti-4822合金的磨削性能，提出了一种基于单磨粒磨削和动态活性磨粒磨削仿真相结合的磨削力预测模型。通过单因素试验和正交试验，分析了磨削参数和砂轮种类对LDED Ti-4822合金磨削力、磨削力比、磨削表面形貌、磨屑和显微硬度的影响。实验结果表明，低进给速度、小磨削深度、高磨削速度有利于降低磨削力和表面粗糙度（最小0.19 μm）。与CBN砂轮相比，金刚石砂轮更适合于磨削LDED Ti-4822合金，因为磨削表面更光滑，缺陷更少，砂轮磨损更低。通过磨削LDED Ti-4822合金将产生显著的表面硬化。最高维氏硬度可达776.6HV，磨削硬化层平均深度为20 μm。
Ti-4822 TiAl alloy is a typical intermetallic compound with great potential applications in aeronautics and astronautics and is widely available to high-pressure compressors and low-pressure turbine blades of aero-engines. Laser-directed energy deposition (LDED) is appropriate to form the Ti-4822 parts with complex shapes and structures. However, the LDED Ti-4822 alloy is a typical hard-brittle and difficult machining material with a poor rough surface and thermal conductivity, leading to poor grinding surface integrity. Therefore, in order to investigate and improve the grinding performance of LDED Ti-4822 alloy, a new prediction model of grinding force was proposed based on the combination of single-grain grinding and dynamic active grains grinding simulation. The influence of grinding parameters and grinding wheel category on grinding force, grinding force ratio, grinding surface morphology, grinding debris, and microhardness of LDED Ti-4822 alloy was analyzed by the single-factor and orthogonal experiments. The experimental results demonstrated that low feed speed, small grinding depth, and high grinding speed are beneficial to reduce grinding force and surface roughness (minimum 0.19 μm). Compared with the CBN wheel, the diamond wheel is more appropriate for grinding LDED Ti-4822 alloy because of a smoother grinding surface with less defects and lower wheel wear. Significant surface hardening will be generated by grinding LDED Ti-4822 alloy. The maximum Vickers hardness can reach 776.6 HV, and the mean depth of grinding hardened layer is 20 μm.