IMTS 2018 Conference: High Performance Grinding (HPG) of Nickel-based Superalloys

Plan to attend The IMTS 2018 Conferences to gain deeper insights into new manufacturing technologies and ideas!

About the topic

High Performance Grinding (HPG) has been defined as any grinding process that enables higher material removal rates while achieving the same surface quality [1]. This type of grinding process effectively reduces the cost and time required for production, thereby achieving efficiency in production. HPG broadens the field of application of grinding from terminal/secondary finishing processes to include frontal/primary material removal process as well. Together with the technological advances of modern machine tools, innovative grinding wheels that consist of engineered/shaped abrasives and high strength bonds provide the main driving force for HPG processes. Grinding with these abrasive wheels can achieve very high material removal rates (MRR), without impacting the quality and metallurgy of components made from difficult-to-machine materials such as nickel-based superalloys. Nickel-based superalloys, which constitute greater than 40% of the total weight of an aircraft engine, find applications in the combustor and turbine sections of the engine. Their use is primarily on account of the unique combination of high temperature strength, toughness and resistance to degradation in extreme environments. These properties also make them difficult to machine and render high-speed machining of components, made from these superalloys, almost impractical. Only specific abrasive wheels that remove stock at low threshold power/forces and consume lower specific energy in grinding of these superalloys, can survive the conflicting goals of higher productivity as well higher wheel life in an HPG process. 

Registration opens soon, so check out the IMTS 2018 website for more information.

This presentation will focus on educating the attendee on each of the innovative features in modern grinding that enable HPG of nickel-based superalloys. Results and data from grinding tests of IN718, Waspalloy and other nickel-based superalloys will be presented. To compare and contrast, available data from machining of these superalloys will also be presented. Furthermore, data on the impact of change in coolant type (oil vs. water soluble coolant) on the HPG process will also be shown to emphasize the criticality of coolant. At the conclusion of this presentation, the attendees will have a deeper understanding of how HPG as a material removal process can play a major role in the roughing and finishing of components made from this important class of work materials in the aerospace industry.

References

Klocke, F., Barth, S., Mattfeld, P. “High Performance Grinding”, Proceedia CIRP 46 (2016) 266-271

Meet your presenter

Dr. K. Philip Varghese has worked for Saint-Gobain Abrasives since 2011, leading the Advanced Application Engineering team, process improvements, customer projects, international team training and development, and technology across Saint-Gobain’s Grinding Technology Centers. Prior to this, he worked as Chief Scientific Officer for CR Foundation leading a team of scientists and engineers focusing on dental product and materials evaluation. He has a PhD in Mechanical Engineering from the University of Utah and an M.S. in Mechanical Engineering from the University of Michigan in Ann Arbor, Michigan. He has presented at numerous industry conferences and trade shows and has authored 23 technical papers and articles in the field of machining, dental products/materials, and grinding technology.