Influence of grinding lubrication methods on surface integrity of nickel-based single crystal superalloy
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摘要: 为提高镍基单晶高温合金DD5的磨削表面质量，采用单因素试验探究3种磨削加工方法（干磨削、传统浇注式、微量润滑（minimum quantity lubrication, MQL））对其表面完整性的影响。结果表明：在不同冷却条件下，DD5磨削表面粗糙度从低到高依次为MQL、传统浇注式、干磨削方式下的。当砂轮线速度较小时，磨削表面质量较差，存在较深划痕和沟槽；当砂轮线速度较大时，磨削表面质量较好，磨痕较小，且分布均匀。在距磨削表面为5～15 μm时，DD5亚表面显微硬度随着深度的增加而急剧下降；在距磨削表面为20～150 μm时，DD5亚表面显微硬度趋于平衡，其在540 HV附近波动。Abstract: To improve the grinding surface quality of nickel-based single crystal superalloy DD5, the influence of three grinding methods (dry, conventional flood, minimal quantity lubrication) on their surface integrity was investigated using single factor experiment. The results show that under different cooling conditions, the grinding surface roughness of nickel-based single crystal superalloy DD5 is MQL, conventional flood and dry grinding from low to high. When the linear speed of the grinding wheel is small, the grinding surface quality is poor, and there are deep scratches and grooves; when the linear speed of the grinding wheel is large, the grinding surface quality is good, the grinding marks are small and evenly distributed. When the depth from the grinding surface is 5~15 μm, the subsurface microhardness of DD5 decreases sharply with the increase of depth. When the depth from the grinding surface is 20~150 μm, the subsurface microhardness of DD5 tends to balance and fluctuates around 540 HV.
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图 2 镍基单晶高温合金DD5金相组织
Figure 2. Metallographic structure of nickel-based single crystal superalloy DD5
图 3 砂轮线速度对表面粗糙度的影响
Figure 3. Effect of grinding wheel linear speed on surface roughness
图 6 不同砂轮线速度下的磨削表面形貌
Figure 6. Grinding surface morphology under different grinding wheel linear speeds
图 7 不同砂轮线速度下的磨削表面三维轮廓
Figure 7. Grinding surface three-dimensional profile under different grinding wheel linear speeds
图 9 不同冷却条件下的磨削亚表面显微硬度
Figure 9. Microhardness of grinding subsurface under different cooling conditions
表 1 磨削表面粗糙度单因素试验结果
Table 1. Single factor experiment results of grinding surface roughness
条件 砂轮线
速度
vs / (m·s−1)磨削
深度
ap / µm进给速度
vf / (m·min−1)表面粗糙度Ra / μm 干磨削 传统
浇注式MQL 1 15 60 0.6 0.983 0.843 0.775 2 20 60 0.6 0.927 0.815 0.734 3 25 20 0.6 0.826 0.685 0.627 4 25 40 0.6 0.865 0.693 0.632 5 25 60 0.6 0.896 0.767 0.658 6 25 80 0.6 0.923 0.796 0.713 7 25 100 0.6 0.955 0.835 0.754 8 25 60 0.2 0.853 0.746 0.629 9 25 60 0.4 0.879 0.757 0.637 10 25 60 0.8 0.926 0.778 0.673 11 25 60 1.0 0.986 0.794 0.688 12 30 60 0.6 0.861 0.742 0.626 13 35 60 0.6 0.809 0.703 0.614 
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