Simulation and experimental thermal analysis of ultrasonic vibration-assisted high-efficiency deep grinding of γ-TiAl blade tenon

• Published in: Applied thermal engineering 2025-01, Vol.258, p.124629, Article 124629
• Main Authors: Zhao, Biao, Wang, Xiaowei, Chen, Tao, Ding, Wenfeng, Qian, Ning, Xu, Jiuhua
• Format: Article
• Language: English
• Subjects: Form grinding; Grinding temperature field; Heat flux; Ultrasonic vibration-assisted high-efficiency deep grinding; γ-TiAl intermetallic compound
• ISSN: 1359-4311
• DOI: 10.1016/j.applthermaleng.2024.124629

•UVHEDG is proposed for reducing grinding temperature of γ-TiAl materials.•3D heat source model is developed combining UVHEDG machining characteristics.•Temperature predicting accuracy is constrained within 15 % using provided models.•Top zone of the tenon tooth has the highest grinding temperature along tooth profile. Gamma titanium-aluminum intermetallic compounds (γ-TiAl) have attracted considerable attention in the aerospace industry because of their outstanding thermal stability and broad range of properties. To analyze the grinding temperature during high-efficiency deep grinding (HEDG) and ultrasonic vibration-assisted high-efficiency deep grinding (UVHEDG) of γ-TiAl materials, both an analytical thermal model and a finite element simulation model were developed. Subsequent comparison trials between HEDG and UVHEDG were conducted to validate the accuracy of the simulation. The results show that the final prediction error can be effectively maintained within 15 %, and the temperature measurement curve fits well when an ultrasonic heat influence factor is incorporated into the 3D finite element model. The introduction of ultrasonic vibrations into the HEDG reduced the maximum grinding temperature by 39.1 %, effectively preventing grinding burns. The highest temperature consistently occurred in the top zone of the blade tenon tooth due to different heat conduction paths caused by the complex profile. This led to a 32.4 % and 31.9 % reduction in the grinding temperature in the bottom zone under HEDG and UVHEDG, respectively. The surface roughness of the machined blade tenon tooth reached 0.664 μm at the top and 0.721 μm at the bottom under UVHEDG, whereas it was 0.735 μm and 0.843 μm under HEDG.