Nickel Superalloy Components Surface Integrity Control through Numerical Optimization

Different parameters are used to evaluate the machined surface quality; roughness, residual stress and white layer are the most common factors that affect the surface integrity. Residual stress, in addition, are one of the main factors that influence the component fatigue life. Superficial residual...

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Bibliographic Details
Published in:Key engineering materials 2014-05, Vol.611-612, p.1396-1403
Main Authors: Mariano, Emilia, Franchi, Rodolfo, Del Prete, Antonio
Format: Article
Language:English
Subjects:
Automation
Integrity
Mathematical models
Optimization
Residual stress
Roughness
Superalloys
Thrust force
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Summary:Different parameters are used to evaluate the machined surface quality; roughness, residual stress and white layer are the most common factors that affect the surface integrity. Residual stress, in addition, are one of the main factors that influence the component fatigue life. Superficial residual stresses depend on different factors, such as cutting parameters and tool geometry. This article describes the development of an automated optimization procedure that allows the matching of a residual stress Target Profile by varying process parameters and tool geometry for a typical aeronautic superalloy, such as Waspaloy, for which a reliable numerical model has been developed for comparison to experimental data. The objective of this procedure is to maximize the Material Removal Rate under physical constraints represented by appropriate limits assigned to: Cutting Force, Thrust Force, Tool Rake Temperature and residual stress Target Profile. The developed optimization procedure has shown its effectiveness to match a given residual stress profile in accordance to process responses numerically evaluated.
ISSN:1013-9826
1662-9795
1662-9795
DOI:10.4028/www.scientific.net/KEM.611-612.1396