Effect of Grinding Temperatures on the Surface Integrity of a Nickel-based Superalloy

An experimental study was carried out to investigat e the influence of temperatures on workpiece surface integrity in surface grinding of a cast nickel-based superalloy with alumina abrasive wheels. Temperatur e response at the wheel-workpiece interface was measured using a grindable foil /workpiece thermocouple. Specimens with different grinding temperatures were obt ained through changing grinding conditions including depth of cut, workpiece fee d speed, and coolant supply. Changes in surface roughness, residual stress, meta llographies, ground surface morphology, and micro hardness on the specimens were then analyzed. Bending fatigue tests were separately conducted at room temperat ure and 950oC in an effort to evaluate the influence of temperatures on the serv ice life of the ground specimens. A different burning color was found on the gro und workpiece surfaces when grinding temperatures are over a critical value. Alo ng with the emergence of burning color, roughness of the ground workpiece surfac e increased greatly compared with the surfaces without burning color, which was attributed to the plastically deformed coatings on the workpiece surface with el evated temperatures. Excepting the surface roughness, other items concerning the surface integrity of the ground workpiece were not affected by temperatures pro vided that grinding temperatures are not high enough to cause grinding cracks. B ased on the findings in this study, the grinding of the nickel-based superalloy can be divided into two stages in order to increase production efficiency, in which case the first stage is to reach an high material removal rate without concerning of the presence of burning color, whereas the second stage is to remo ve the plastically deformed coatings in order to decrease surface roughness.