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Metals 2018, 8(1), 24; https://doi.org/10.3390/met8010024

Super Abrasive Machining of Integral Rotary Components Using Grinding Flank Tools

1
Department of Mechanical Engineering, University of the Basque Country (UPV/EHU), Alameda de Urquijo s/n, 48013 Bilbao, Spain
2
CFAA—University of the Basque Country (UPV/EHU), Parque Tecnológico de Zamudio 202, 48170 Bilbao, Spain
3
BCAM—Basque Center for Applied Mathematics, Alameda de Mazarredo 14, 48009 Bilbao, Spain
*
Author to whom correspondence should be addressed.
Received: 28 November 2017 / Revised: 28 December 2017 / Accepted: 29 December 2017 / Published: 1 January 2018
(This article belongs to the Special Issue Machining and Finishing of Nickel and Titanium Alloys)
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Abstract

Manufacturing techniques that are applied to turbomachinery components represent a challenge in the aeronautic sector. These components require high resistant super-alloys in order to satisfy the extreme working conditions they have to support during their useful life. Besides, in the particular case of Integrally Bladed Rotors (IBR), usually present complex geometries that need to be roughed and finished by milling and grinding processes, respectively. In order to improve their manufacturing processes, Super Abrasive Machining (SAM) is presented as a solution because it combines the advantages of the use of grinding tools with milling feed rates. However, this innovative technique usually needed high tool rotary speed and pure cutting oils cooling. These issues implied that SAM technique was not feasible in conventional machining centers. In this work, these matters were tackled and the possibility of using SAM in these five-axis centers with emulsion coolants was achieved. To verify this approach, Inconel 718 single blades with non-ruled surfaces were manufactured with Flank-SAM technique and conventional milling process, analyzing cutting forces, surface roughness, and dimension accuracy in both cases. The results show that SAM implies a suitable, controllable, and predictable process to improve the manufacture of aeronautical critical components, such as IBR. View Full-Text
Keywords: Blisk machining; super abrasive machining; SAM; Inconel 718 machining Blisk machining; super abrasive machining; SAM; Inconel 718 machining
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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González, H.; Calleja, A.; Pereira, O.; Ortega, N.; López de Lacalle, L.N.; Barton, M. Super Abrasive Machining of Integral Rotary Components Using Grinding Flank Tools. Metals 2018, 8, 24.

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