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<p>The grindability of the third-generation single-crystal nickel alloy (3rd SX) and the second-generation single-crystal nickel alloy (2nd SX) was studied comparatively with creep feed grinding using two separate L16 fractional factorial Taguchi experimental trails. Typically, 3rd SX presents more difficulties than 2nd SX in grinding with the 9.4% higher average grinding force, 9% higher average&#xa0;grinding temperature, and 15% higher average workpiece surface roughness. Meantime, SG wheel shows the best performance in grinding of SX alloys. A combination of a moderate level operating parameters: 35&#xa0;m/s grinding speed, 0.5&#xa0;mm grinding depth, and 480&#xa0;mm/min feed rate, produces crack-free surface of SX alloy with the average surface roughness of Ra = 0.3&#xa0;µm. Surface integrity examination at micro-/nanoscales indicates that SX alloy subsurface forms nanosized grains (about 30–200&#xa0;nm in size) in top surface of 500&#xa0;nm deep from the ground surface. Furthermore, at low grinding temperatures, the nanosized refinement of original single crystal texture is derived from the crystal defects created by plastic deformation that induced by grinding process. While at ultra-high grinding temperatures of more than 1100 ℃, the refined grains due to plastic deformation changes into the nucleation of dynamic recrystallization (DRX) and eventually into recrystallization texture. Microhardness evaluation demonstrates that SX alloys with SG wheels show a hardened layer to a depth of 20–60&#xa0;µm with the hardening level from 27–41%.</p>

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Grindability evaluation of different single-crystal nickel alloys in creep-feed grinding based on the Taguchi method

  • 期刊论文

  • 发表日期：

    2025年5月7日

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  • Shuaiqi Zhang,
  • Lijie Hu,
  • Yunsong Zhao,
  • Wenfeng Ding,
  • Biao Zhao,
  • Qing Miao,
  • Hexu You

摘要

The grindability of the third-generation single-crystal nickel alloy (3rd SX) and the second-generation single-crystal nickel alloy (2nd SX) was studied comparatively with creep feed grinding using two separate L16 fractional factorial Taguchi experimental trails. Typically, 3rd SX presents more difficulties than 2nd SX in grinding with the 9.4% higher average grinding force, 9% higher average grinding temperature, and 15% higher average workpiece surface roughness. Meantime, SG wheel shows the best performance in grinding of SX alloys. A combination of a moderate level operating parameters: 35 m/s grinding speed, 0.5 mm grinding depth, and 480 mm/min feed rate, produces crack-free surface of SX alloy with the average surface roughness of Ra = 0.3 µm. Surface integrity examination at micro-/nanoscales indicates that SX alloy subsurface forms nanosized grains (about 30–200 nm in size) in top surface of 500 nm deep from the ground surface. Furthermore, at low grinding temperatures, the nanosized refinement of original single crystal texture is derived from the crystal defects created by plastic deformation that induced by grinding process. While at ultra-high grinding temperatures of more than 1100 ℃, the refined grains due to plastic deformation changes into the nucleation of dynamic recrystallization (DRX) and eventually into recrystallization texture. Microhardness evaluation demonstrates that SX alloys with SG wheels show a hardened layer to a depth of 20–60 µm with the hardening level from 27–41%.