To investigate the subsurface damage mechanism of nickel-based superalloys during the grinding process, the work aims to compare the changes in subsurface defects induced by vibration-assisted grinding and conventional grinding and further explore how vibration-assisted grinding affects the subsurface damage characteristics of nickel-based superalloys.
A single-grain grinding model of nickel-based superalloys using cubic boron nitride (CBN) tools under vibration assistance was established through molecular dynamics simulations. Based on simulation results, the microscopic subsurface damage mechanisms were analyzed. By integrating simulation with experimental data, variations in grinding forces, as well as the number, types, and dislocation behaviors of subsurface defect atoms under both vibration-assisted and conventional grinding conditions were compared. The effects of vibration assistance on subsurface damage formation were thoroughly examined.
Through the investigation of the subsurface damage mechanism in nickel-based superalloys under vibration-assisted grinding, it was observed that as abrasive grains continued to advance across the workpiece surface, the initial face-centered cubic (FCC) structure within the material progressively transformed into a hexagonal close-packed (HCP) structure during the grinding process. The HCP structure represented a form of crystallographic defect and was primarily composed of dislocation defects, vacancy defects, atomic clusters, and stacking faults. An increase in HCP content indicated a corresponding increase in subsurface defects within the workpiece. Furthermore, V-shaped dislocations were also generated during the grinding process, which were recognized as a significant contributing factor to subsurface damage in nickel-based superalloys.
A comparative analysis of grinding forces between conventional grinding and vibration-assisted grinding reveals that both tangential and normal forces are substantially reduced in the vibration-assisted process. The number of subsurface defects in nickel-based superalloys is significantly lower during vibration-assisted grinding compared to conventional grinding, indicating that vibration-assisted grinding effectively suppresses the formation of stacking faults and dislocation defects. Furthermore, the subsurface damage depth in nickel-based superalloys subject to vibration-assisted grinding markedly decreases relative to that observed in conventional grinding. By using dislocation extraction techniques to investigate dislocation evolution in nickel-based superalloys, it is found that vibration-assisted grinding inhibits the formation of V-shaped dislocations, thereby mitigating subsurface damage in these materials.
The microstructure of subsurface damage layers formed during vibration-assisted grinding and conventional grinding is analyzed with transmission electron microscopy (TEM). The results indicate that the subsurface damage depth in nickel-based single-crystal superalloys subject to conventional grinding is approximately 2.27 μm, whereas in vibration-assisted grinding, the damage depth is significantly reduced to approximately 39.5 nm. Experimental validation confirms that vibration-assisted grinding effectively reduces the extent of subsurface damage in nickel-based superalloys, aligning with both simulation and theoretical predictions.
The results demonstrate that upon contact between the grinding tool and the workpiece, the original lattice structure of the workpiece undergoes deformation, leading to subsurface defects within the crystal lattice and subsequently inducing subsurface damage. When vibration is applied to the grinding process, both the grinding force and the depth of subsurface damage are significantly reduced. Additionally, vibration effectively suppresses the formation of lamellar dislocations, dislocation clusters, and V-shaped dislocations, thereby decreasing the number of defect atoms in the subsurface region and minimizing the overall extent of subsurface damage in nickel-based superalloys.
Key words
vibration-assisted grinding /
nickel-based superalloys /
subsurface damage /
molecular dynamics /
dislocation
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Funding
National Natural Science Foundation of China (52375404)
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