In the aerospace industry, the Ti-6Al-4V alloy stands out due to a unique combination of properties such as low density (4 g⋅cm−3) and mechanical resistance at high temperatures allowing it to be employed in manufacturing of several components, such as engine blades and fuselage parts. Therefore, for the manufacture of these components, it is essential knowledge about the effects of the machining processes involved so that the tolerances specified in the project are met, mainly regarding roughness and dimensional deviations. However, this specific alloy is considered a material that is difficult to grind due to its low thermal conductivity (6.6 W⋅(m⋅K)−1) and high chemical reactivity with the ceramic materials that make up the grinding wheels. One of the main parameters that influence grinding is dressing, a conditioning operation that directly influences the surface quality of the part being machined. In this sense, this work aimed to evaluate the effects that 2 different dressing depth conditions (ad = 20 µm and ad = 40 µm) can have on the surface quality of the Ti-6Al-4V aeronautical alloy after grinding. The tests were carried out with a silicon carbide grinding wheel (C46K5V5), cutting speed of 38.3 m/s, workspeed 7 m/min and radial depth of cut of 20 µm. Surface quality was evaluated in terms of the roughness parameter Ra and the texture of the samples obtained via Scanning Electron Microscopy (SEM) images. A methodology to evaluate the measurement uncertainty associated with the Ra roughness parameters was developed and the results showed that the change in dressing depth from a severest condition, dressing depth of ad = 40 µm to a soft condition ad = 20 µm resulted up to 25.51% reduction in roughness Ra. From the images of the samples was possible to identify an increase in number of the displacement and detachment of material from the sample, as well as the presence of thermal cracks after machining with under severest dressing condition.

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Influence of Dressing Depth on the Roughness and Surface Texture of Aeronautical Alloy During Grinding

  • Mayara Fernanda Pereira,
  • Bruno Souza Abrão,
  • Amanda Souza Abrão,
  • Anna Beatriz Vaz Martins,
  • Amauri Hassui,
  • Rosemar Batista da Silva

摘要

In the aerospace industry, the Ti-6Al-4V alloy stands out due to a unique combination of properties such as low density (4 g⋅cm−3) and mechanical resistance at high temperatures allowing it to be employed in manufacturing of several components, such as engine blades and fuselage parts. Therefore, for the manufacture of these components, it is essential knowledge about the effects of the machining processes involved so that the tolerances specified in the project are met, mainly regarding roughness and dimensional deviations. However, this specific alloy is considered a material that is difficult to grind due to its low thermal conductivity (6.6 W⋅(m⋅K)−1) and high chemical reactivity with the ceramic materials that make up the grinding wheels. One of the main parameters that influence grinding is dressing, a conditioning operation that directly influences the surface quality of the part being machined. In this sense, this work aimed to evaluate the effects that 2 different dressing depth conditions (ad = 20 µm and ad = 40 µm) can have on the surface quality of the Ti-6Al-4V aeronautical alloy after grinding. The tests were carried out with a silicon carbide grinding wheel (C46K5V5), cutting speed of 38.3 m/s, workspeed 7 m/min and radial depth of cut of 20 µm. Surface quality was evaluated in terms of the roughness parameter Ra and the texture of the samples obtained via Scanning Electron Microscopy (SEM) images. A methodology to evaluate the measurement uncertainty associated with the Ra roughness parameters was developed and the results showed that the change in dressing depth from a severest condition, dressing depth of ad = 40 µm to a soft condition ad = 20 µm resulted up to 25.51% reduction in roughness Ra. From the images of the samples was possible to identify an increase in number of the displacement and detachment of material from the sample, as well as the presence of thermal cracks after machining with under severest dressing condition.