International Journal of Extreme Manufacturing, Volume. 6, Issue 3, 35101(2024)

Improving fatigue properties of normal direction ultrasonic vibration assisted face grinding Inconel 718 by regulating machined surface integrity

Nianwei Xu1... Renke Kang1, Bi Zhang2, Yuan Zhang1, Chenxu Wang1, Yan Bao1 and Zhigang Dong1,* |Show fewer author(s)
Author Affiliations
  • 1State Key Laboratory of High-Performance Precision Manufacturing, Dalian University of Technology,Dalian 116024, People’s Republic of China
  • 2Department of Mechanical and Energy Engineering, Southern University of Science and Technology,Shenzhen 518055, People’s Republic of China
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    Fatigue properties are crucial for critical aero-engine components in extreme service environments, which are significantly affected by surface integrity (SI) indexes (especially surface topography, residual stress σres, and microhardness) after machining processes. Normal-direction ultrasonic vibration-assisted face grinding (ND-UVAFG) has advantages in improving the machinability of Inconel 718, but there is a competitive relationship between higher compressive σres and higher surface roughness Ra in affecting fatigue strength. The lack of a quantitative relationship between multiple SI indexes and fatigue strength makes the indeterminacy of a regulatory strategy for improving fatigue properties. In this work, a model of fatigue strength (σf)sur considering multiple SI indexes was developed. Then, high-cycle fatigue tests were carried out on Inconel 718 samples with different SI characteristics, and the influence of ND-UVAFG process parameters on SI was analyzed. Based on SI indexes data, the (σf)sur distribution in the grinding surface layer for ND-UVAFG Inconel 718 samples was determined using the developed model, and then the fatigue crack initiation (FCI) sites were further predicted. The predicted FCI sites corresponded well with the experimental results, thereby verifying this model. A strategy for improving the fatigue life was proposed in this work, which was to transfer the fatigue source from the machined surface to the bulk material by controlling the SI indexes. Finally, a critical condition of SI indexes that FCI sites appeared on the surface or in bulk material was given by fitting the predicted results. According to the critical condition, an SI field where FCI sites appeared in the bulk material could be obtained. In this field, the fatigue life of Inconel 718 samples could be improved by approximately 140%.

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    Nianwei Xu, Renke Kang, Bi Zhang, Yuan Zhang, Chenxu Wang, Yan Bao, Zhigang Dong. Improving fatigue properties of normal direction ultrasonic vibration assisted face grinding Inconel 718 by regulating machined surface integrity[J]. International Journal of Extreme Manufacturing, 2024, 6(3): 35101

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    Paper Information

    Received: May. 17, 2023

    Accepted: --

    Published Online: Sep. 11, 2024

    The Author Email: Dong Zhigang (dongzg@dlut.edu.cn)

    DOI:10.1088/2631-7990/ad33aa

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