Experiment on Surface Quality in Micro-milling of Single Crystal Ni-Based Superalloy DD98

doi:10.12068/j.issn.1005-3026.2017.03.017

Abstract

Abstract: To study the micro-milling surface quality of single crystal superalloy， orthogonal experiment was implemented for micro-milling of single crystal Ni-based superalloy DD98 by using the M.A.FORD two-edged micro-milling tool with 0.8mm diameter. The primary and secondary impacting factors on the micro-milling surface quality， such as spindle speed， feed rate and milling depth were analyzed by range analysis. The results show that the influence of spindle speed is the greatest， the milling depth is the secondary， while the feed rate is the smallest. Using statistical theory， the ideal cutting process parameters was optimized and obtained， i.e， 3.6kr/min speed spindle， 5μm milling depth and 100μm/s feed rate. The surface roughness is minimum under the above combination condition. The experiments were repeatedly done with the optimized scheme to get a surface roughness (R_a) of 951nm. The cutting mechanism， the reasons of affecting surface quality and morphology were further analyzed. The experiment result may provide some reference for micro-milling mechanism of single crystal superalloy.

Key words: micro-milling, single crystal, Ni-based superalloy, surface roughness, DD98

CLC Number:

TH161

GAO Qi， GONG Ya-dong， ZHOU Yun-guang， WEN Xue-long. Experiment on Surface Quality in Micro-milling of Single Crystal Ni-Based Superalloy DD98[J]. Journal of Northeastern University Natural Science, 2017, 38(3): 385-389.

References

[1]王震，李金国，金涛.熔体过热处理对DD98镍基单晶高温合金持久性能的影响［J］.金属热处理，2012，37(4):48-51.(Wang Zhen，Li Jin-guo，Jin Tao.Influence of melt over-heating treatment on stress rupture properties of DD98 Ni-based single crystal superalloy［J］.Heattreatment of Metals，2012，37(4):48-51.)
[2]高奇，蔡明.高速微尺度铣削单晶铝表面粗糙度试验研究［J］.组合机床与自动化加工技术，2016，9(9):13-16.(Gao Qi，Cai Ming.Experimental study on surface roughness in high speed micro milling of single crystal aluminum［J］.Modular Machine Tool and Automatic Manufacturing Technique，2016，9(9):13-16.)
[3]高奇，巩亚东，周云光.单晶Ni3Al基高温合金微铣削表面粗糙度试验研究［J］.中国机械工程，2016，27(6):801-804.(Gao Qi，Gong Ya-dong，Zhou Yun-guang.Experimental study on surface quality in micro-milling of single crystal Ni3Al-based superalloy［J］.China Mechanical Engineering，2016，27(6):801-804.)
[4]陈明君，陈妮，何宁，等.微铣削加工机理研究新进展［J］.机械工程学报，2014，50(5):161-172.(Chen Ming-jun，Chen Ni，He Ning，et al.The research progress of micromilling in machining mechanism［J］.Journal of Mechanical Engineering，2014，50(5):161-172.)
[5]高奇，巩亚东，蔡明，等.单晶硅微铣削塑性去除表面质量实验研究［J］.制造技术与机床，2016(6):135-138.(Gao Qi，Gong Ya-dong，Cai Ming，et al.Experimental study on surface quality in micro-milling of single crystal Si plastic removal［J］.Manufacturing Technology and Machine Tool，2016(6):135-138.)
[6]Sato M，Yamazaki T，Shimizu Y，et al.A study on the microcutting of aluminum single crystals［J］.JSME International Journal Series III，1991，34(4):540-545.
[7]Lucca D A，Seo Y W.Effect of tool edge geometry on energy dissipation in ultra-precision machining ［J］.CIRP Annals，1993，42(1):83-86.
[8]Lucca D A，Seo Y W.Aspects of surface generation in orthogonal ultra-precision machining ［J］.CIRP Annals， 1994，43(1):43-46.
[9]Damazo B N，Davies M A，Dutterer B S，et al.A summary of micro-milling studies［C］//First International Conference of the European Society for Precision Engineering and Nanotechnology.Bremen，1999:322-324.
[10]Schaller T，Bohn L，Mayer J，et al.Microstructure grooves with a width of less than 50 μm cut with ground hard metal micro end mills［J］.Precision Engineering，1999(23):229-235.

[1]	FANG Rui， ZOU Ping， DUAN Jing-wei， WEI Shi-yu. Experimental Research on Friction Reduction Characteristics and Surface Quality of 3D Ultrasonic Vibration Assisted Turning [J]. Journal of Northeastern University(Natural Science), 2023, 44(2): 233-241.
[2]	LU Xiao-hong， GU Han， CONG Chen， RUAN Fei-xiang. Micro-milling Force Prediction of Inconel 718 Thin-walled Parts [J]. Journal of Northeastern University(Natural Science), 2023, 44(2): 242-250.
[3]	JIANG Shi-jie， HU Ke， CHEN Pi-feng， ZHAN Ming. Theoretical and Experimental Investigation on the Three-Dimensional Surface Roughness of Fused Filament Fabrication Products [J]. Journal of Northeastern University(Natural Science), 2022, 43(9): 1290-1297.
[4]	WEN Xue-long， WANG Cheng-bao， GONG Ya-dong， SUN Fu-qiang. Preparation of Coated Micro-grinding Tools and Experimental Research on Grinding Surface Quality [J]. Journal of Northeastern University(Natural Science), 2022, 43(5): 681-688.
[5]	WEN Xue-long， LI Jia-yu， LI Xin-yan. Influencing Factors of Grinding Surface Quality of TiC-Coated Micro-grinding Tools [J]. Journal of Northeastern University(Natural Science), 2022, 43(4): 534-540.
[6]	ZHOU Yun-guang， TIAN Chuan-chuan， MA Lian-jie， BI Chang-bo. Experimental Study on Surface Quality in Micro-scale Grinding of Zirconia Ceramics [J]. Journal of Northeastern University(Natural Science), 2022, 43(1): 83-88.
[7]	ZHAO Chun-yu， CHENG Da-zhong， GENG Hao-bo. Research on 2-D Surface Topography Detection Method of Turning Workpieces [J]. Journal of Northeastern University(Natural Science), 2021, 42(9): 1299-1306.
[8]	JIANG Shi-jie， HU Ke， CHEN Pi-feng， SIYAJEU Yannick. Theoretical Model and Experimental Verification of Surface Roughness of Fused Filament Fabrication Plates [J]. Journal of Northeastern University(Natural Science), 2021, 42(7): 980-986.
[9]	JIAO An-yuan， ZHANG Guo-fu， DING Hao-dong， LIU Wei-jun. Experiment of Magnetic Abrasive Finishing on TC4 Titanium Alloy Hole [J]. Journal of Northeastern University Natural Science, 2020, 41(9): 1304-1310.
[10]	GONG Ya-dong， SU Zhi-peng， SUN Yao， JIN Li-ya. Morphology Simulation and Experimental Study on Micro-grinding of Nickel-Based Single Crystal Superalloy [J]. Journal of Northeastern University Natural Science, 2020, 41(7): 949-954.
[11]	GONG Ya-dong， ZHANG Wei-jian， CAI Ming， ZHOU Xian-xin. Experimental Study on the Grinding Metamorphic Layer of Nickel-based Single Crystal Superalloy [J]. Journal of Northeastern University Natural Science, 2020, 41(6): 846-851.
[12]	WEN Xue-long， YU Xing-chen， GONG Ya-dong， MENG Fan-tao. Grinding Mechanism and Surface Roughness of FeCoNiCrMo High-Entropy Alloy [J]. Journal of Northeastern University Natural Science, 2020, 41(2): 246-251.
[13]	QU Shuo-shuo， GONG Ya-dong， YANG Yu-ying， SHE Yue-bin. Research on Grinding Process Performance of 2.5D C_f/SiC [J]. Journal of Northeastern University Natural Science, 2020, 41(2): 252-257.
[14]	LIU Yu， CHEN Qi-sen， DONG Qiu-shi. Temperature Prediction Model of Bone Material Micro-milling Cutting Edges [J]. Journal of Northeastern University Natural Science, 2020, 41(11): 1615-1622.
[15]	GONG Ya-dong， MENG Fan-tao， SUN Yao， YU Xing-chen. Experimental Study on Micro-hole Processing of Nickel-Based Single Crystal Superalloy [J]. Journal of Northeastern University Natural Science, 2020, 41(1): 84-89.