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Subsurface deformation and burr formation in nickel-based single-crystal superalloy under grinding

Liang Chunyou, Gong Yadong, Li Pengfei, Sun Jingyu, Jin Liya, Yin Guoqiang, Wen Xuelong, Bo Xin

Archives of Civil and Mechanical Engineering

2023

Vol. 23, no. 2

art. no. e126, 2023

Machined subsurface and burr of nickel-based single-crystal superalloys (SXs) were identified as a key factor to the aero-engine industrial requirements concerning high service performance and the precision of edge geometry, in particular the finishing operations as grinding. To clarify subsurface deformation behaviors and the mechanisms of burr formation when grinding SXs, first, the present investigation predicted slip stresses acting on slip systems in workpiece subsurface under grinding based on the theory of resolved shear stress in single crystal, and correlated theoretical possible slip traces with experimental observed slip band systems. Second, grinding experiments on nickel-based SXs with [00-1]/[010], [11-3]/[332], [-110]/[111] and [-1-1-1]/[-110] orientations were performed to determine the anisotropy deformational behaviors of workpiece subsurface. Lastly, the unreported free surface of burr was adopted to investigate the formation mechanisms for side burrs and exit burrs during grinding. Results show that subsurface deformation patterns present anisotropy and resolved shear stress contribute to slip in nickel-based SXs. High shear density layers/zones consisting of interacted slip bands are found in grinding-induced sub-surfaces. Slip induced plasticity is the dominant deformation mechanism in the formation process of side burrs and exit burrs in grinding of nickel-based SXs.