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Improvement of titanium alloy TA19 fatigue life by submerged abrasive waterjet peening:Correlation of its process parameters with surface integrity and fatigue performance

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Chinese Journal of Aeronautics 2024年第1期37卷 377-390页

作者： Gongyu WANG Shulei YAO Yuxin CHI Chengcheng ZHANG Ning WANG Yalong CHEN Rongsheng LU Zhuang LI Xiancheng ZHANG Key Laboratory of Pressure Systems and Safety Ministry of EducationSchool of Mechanical and Power EngineeringEast China University of Science and TechnologyShanghai 200237China AECC Commercial Aircraft Engine Co.LTD Shanghai Engineering Research Center for Commercial Aircraft EngineShanghai 201108China

Submerged abrasive waterjet peening(SAWJP)is an effective anti-fatigue manufacturing technology that is widely used to strengthen aeroengine *** study investigated the correlation of SAWJP process parameters on surface integrity and fatigue life of titanium alloy *** with different water pressures and standoff distances(SoDs)was conducted on the TA19 *** surface integrity of the specimens before and after SAWJP with different process parameters was experimentally studied,including microstructure,surface roughness,microhardness,and compressive residual stress(CRS).Finally,fatigue tests of the specimens before and after SAWJP treatment with different process parameters were carried out at room *** results highlighted that the fatigue life of the TA19 specimen can be increased by 5.46,5.98,and 6.28 times under relatively optimal process parameters,which is mainly due to the improved surface integrity of the specimen after SAWJP ***,the fatigue life of specimens treated with improper process parameters is decreased by 0.55 to 0.69 times owing to the terrible surface roughness caused by the material *** work verifies that SAWJP can effectively improve the surface integrity and fatigue life of workpieces,and reveals the relationship between process parameters,surface integrity,and fatigue life,which provides support for the promotion of SAWJP in the manufacturing fields.

关键词： Fatigue testing Process parameters Submerged abrasive waterjet peening surface integrity surface treatment Titanium alloy TA19

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Improving fatigue properties of normal direction ultrasonic vibration assisted face grinding Inconel 718 by regulating machined surface integrity

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International Journal of Extreme Manufacturing 2024年第3期6卷 458-475页

作者： Nianwei Xu Renke Kang Bi Zhang Yuan Zhang Chenxu Wang Yan Bao Zhigang Dong State Key Laboratory of High-Performance Precision Manufacturing Dalian University of TechnologyDalian 116024People’s Republic of China Department of Mechanical and Energy Engineering Southern University of Science and TechnologyShenzhen 518055People’s Republic of China

Fatigue properties are crucial for critical aero-engine components in extreme serviceenvironments,which are significantly affected by surface integrity(SI)indexes(especially surface topography,residual stressσ_(res),and microhardness)after machining ***-direction ultrasonic vibration-assisted face grinding(ND-UVAFG)has advantages in improving the machinability of Inconel 718,but there is a competitive relationship between higher compressiveσ_(res)and higher surface roughness R_(a)in affecting fatigue *** lack of a quantitative relationship between multiple SI indexes and fatigue strength makes theindeterminacy of a regulatory strategy for improving fatigue *** this work,a model of fatigue strength(σ_f)_(sur)considering multiple SI indexes was ***,high-cycle fatigue tests were carried out on Inconel 718 samples with different SI characteristics,and the influence of ND-UVAFG process parameters on SI was *** on SI indexes data,the(σ_f)_(sur)distribution in the grinding surface layer for ND-UVAFG Inconel 718 samples was determined using the developed model,and then the fatigue crack initiation(FCI)sites were *** predicted FCI sites corresponded well with the experimental results,therebyverifying this model.A strategy for improving the fatigue life was proposed in this work,which was to transfer the fatigue source from the machined surface to the bulk material by controlling the SI ***,a critical condition of SI indexes that FCI sites appeared on the surface or in bulk material was given by fitting the predicted *** to the critical condition,an SI field where FCI sites appeared in the bulk material could be *** this field,thefatigue life of Inconel 718 samples could be improved by approximately 140%.

关键词： surface integrity fatigue strength Inconel 718 ultrasonic assisted grinding

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surface integrity of Inconel 738LC Parts Manufactured by Selective Laser Melting Followed by High-speed Milling

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Chinese Journal of Mechanical Engineering 2023年第1期36卷 65-79页

作者： Guanhui Ren Sai Guo Bi Zhang Department of Mechanical and Energy Engineering Southern University of Science and TechnologyShenzhen518055China Shenzhen Key Laboratory for Additive Manufacturing of High-performance Materials Shenzhen518055China Research and Development Department Shenzhen Xinjinquan Precision Techonology Co.Ltd.Shenzhen518055China School of Mechanical Engineering Shandong UniversityJinan250061China

This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting(SLM)followed by high-speed milling(HSM).In the investigation process of surface integrity,the study employs ultradepth three-dimensional microscopy,laser scanning confocal microscopy,scanning electron microscopy,electron backscatter diffractometry,and energy dispersive spectroscopy to characterize the evolution of material microstructure,work hardening,residual stress coupling,and anisotropic effect of the building direction on surface integrity of the *** results show that SLM/HSM hybrid manufacturing can be an effective method to obtain better surface quality with a thinner machining metamorphic ***-speed machining is adopted to reduce cutting force and suppress machining heat,which is an effective way to produce better surface mechanical properties during the SLM/HSM hybrid manufacturing *** general,high-speed milling of the SLM-built Inconel 738LC samples offers better surface integrity,compared to simplex additive manufacturing or casting.

关键词： surface integrity Inconel 738LC Selective laser melting High-speed milling

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surface integrity of ball burnished bioresorbable magnesium alloy

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Advances in Manufacturing 2023年第2期11卷 342-362页

作者： G.V.Jagadeesh Srinivasu Gangi Setti Department of Mechanical Engineering National Institute of Technology RaipurChhattisgarh492010India

Magnesium alloys are potential biodegradable and biocompatible implant materials because of their excellent biological properties. Recently, interest in these alloys as a promising alternative for temporary orthopedic implants has grown owing to their desirable biological, mechanical, and physical properties. However, the application of magnesium alloys is hindered by their rapid degradation and low corrosion resistance in physiological fluids, leading to the failure of implants. Thus, the current challenge is to enhance the corrosion resistance and control the degradation rate of magnesium under physiological conditions. The rapid degradation of magnesium alloys can be controlled by improving their surface integrity, such as surface roughness and microhardness. The present study aims to improve the surface integrity of the Mg Ze41A alloy by the ball burnishing technique. The surface roughness improved by 94.90% from 0.941 μm to 0.048 μm with a burnishing force of 50 N, burnishing speed of 1 300 r/min, burnishing feed of 130 mm/min, and three passes. Similarly, the microhardness improved by 50.62% from 75.2 HV to 113.27 HV with a burnishing force of 60 N, burnishing speed of 1 100 r/min, burnishing feed of 100 mm/min, and five passes. The variations in microhardness, which were observed up to 400 μm beneath the surface, exhibited a linear nature. These variations may be attributed to the movement of dislocations, formation of new dislocations, nanocrystal structures, metastable phases and subgrains, and lattice distortion or grain refinement. The surface features obtained from optical images demonstrated the fundamental mechanisms involved in the ball burnishing process. The concept of burnishing maps and zones will assist in the design of the ball burnishing parameters of a material with an equivalent yield strength of 140 MPa. The significant improvement in the surface integrity of the Mg Ze41A alloy by the ball burnishing technique is expected to improve its func

关键词： Magnesium alloy Bioresorbable Orthopedic implants surface integrity Ball burnishing

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Experimental investigation of the relation between the surface integrity and bending fatigue strength of carburized gears

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Science China(Technological Sciences) 2023年第1期66卷 33-46页

作者： CHEN DiFa ZHU JiaZan LIU HuaiJu WEI PeiTang MAO TianYu State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China China Gas Turbine Establishment Chengdu 710025China

Bending fatigue is an essential parameter that needs to be considered in the improvement process of the power density and reliability of gear drives. Quantitative relations among the manufacturing parameters, surface integrities, and fatigue performance are not clear, which seriously limits the effectiveness of an anti-fatigue design. For this work, tooth-bending fatigue tests of carburized gears with different surface integrities were performed using a pulsator. The effects of the manufacturing parameters and surface integrities on the gear fatigue, such as surface hardness and residual stress, were investigated. The experimental results revealed that due to the improvement of surface integrities after shot peening, the nominal bending stress number(fatigue limit) increased by 6.3%–31.1%, with an amplitude range of 39–143 MPa. A supervised learning algorithm of a random forest was implemented to determine the contribution of the surface hardness and surface residual stress to the nominal stress number. An empirical formula was proposed to predict the nominal stress number considering the surface integrities. The prediction error was less than 7.53%, as verified by several gear-bending fatigue tests. This provided theoretical support for the modern, anti-fatigue design of the gears.

关键词： carburized gear surface integrity bending fatigue design formula

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Comparison of surface integrity for dry and wet drilling of 49Fe-49Co-2V alloy

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Chinese Journal of Aeronautics 2022年第6期35卷 325-338页

作者： Yuan ZHANG Zhigang DONG Yan BAO Renke KANG Xin HUANG Dongming GUO Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education School of Mechanical EngineeringDalian University of TechnologyDalian 116024China AVIC Xi’an Flight Automatic Control Research Institute Xi’an 710076China

Working performances of the components made out of 49Fe-49Co-2V alloy are closely related to the surface integrity of the drilled holes,which are influenced remarkably by the cooling *** present study focuses on the surface integrity differences between wet and dry drilled 49Fe-49Co-2V alloy *** drilled hole surface roughness and topographies,metallurgical and mechanical properties,and the exit characterizations were obtained using optical microscopy(OM),scanning electron microscopy(SEM),electron backscatter diffraction microscopy(EBSD),transmission electron microscopy(TEM),energy dispersive spectroscopy(EDS)and Vickers hardness techniques,*** effects of cooling conditions on the surface integrity were concluded and the influence mechanisms were analyzed based on the force and temperature differences in drilling process with different cooling *** is found that the surface roughness and the thickness of refined-grain region of the dry drilled holes are larger than those of wet drilled holes;work hardening induced by wet drilling is more serious than dry drilling;chippings occurred in the exits of the wet drilled holes due to the material brittleness,which could be avoided by dry *** surface integrity differences of wet and dry drilled holes are closely related to the force and temperature differences in drilling process with different cooling conditions.

关键词： 49Fe-49Co-2V alloy Cooling condition Drilling Exit chipping Microstructure surface integrity surface quality Work hardening

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Ironing effect on surface integrity and fatigue behavior during ultrasonic peening drilling of Ti-6Al-4V

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Chinese Journal of Aeronautics 2023年第5期36卷 486-498页

作者： Yihang LIU Deyuan ZHANG Daxi GENG Zhenyu SHAO Zehua ZHOU Zhefei SUN Yonggang JIANG Xinggang JIANG School of Mechanical Engineering and Automation Beihang UniversityBeijing 100191China Institute of Bionic and Micro-Nano Systems Beihang UniversityBeijing 100191China Aerospace Times Feihong Technology Company Limited Beijing 100094China

Imposing compressive residual stress field around a fastening hole serves as a universal method to enhance the hole fatigue strength in the aircraft assembly *** Peening Drilling(UPD)is a recently proposed hybrid hole making process,which can achieve an integration of strengthening and precision-machining with a one-shot-drilling *** to the ironing effect of tool flank surface,UPD introduces large compressive residual stress filed in hole *** order to reveal the strengthening mechanism of UPD,the influence of ultrasonic vibration and tool dynamic relief angle on ironing coverage rate and its corresponding effect on surface integrity in UPD were *** experiments were conducted to verify the influence of ironing effect on surface integrity and fatigue behavior of Ti-6Al-4V hole in *** results indicate that the specimen features smaller surface roughness,higher micro-hardness,plastic deformation degree and circumferential compress residual stress under higher ironing coverage *** fatigue life increases with the raise of ironing coverage rate,and the fatigue source site in UPD shifts from surface to subsurface comparing with that without vibration *** results demonstrates that a better strengthening effect can be obtained by reasonably controlling the ironing coverage rate in UPD.

关键词： Fatigue strength surface integrity Titanium alloy Tool relief angle Ultrasonic Peening Drilling(UPD)

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Collaborative manufacturing technologies of structure shape and surface integrity for complex thin-walled components of aero-engine:Status,challenge and tendency

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Chinese Journal of Aeronautics 2023年第7期36卷 1-24页

作者： Biao ZHAO Wenfeng DING Zhongde SHAN Jun WANG Changfeng YAO Zhengcai ZHAO Jia LIU Shihong XIAO Yue DING Xiaowei TANG Xingchao WANG Yufeng WANG Xin WANG College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China School of Mechanical Engineering Northwestern Polytechnical UniversityXi’an 710072China AVIC Manufacturing Technology Institute Beijing 100024China School of Mechanical Science and Engineering Huazhong University of Science and TechnologyWuhan 430074China AECC Shenyang Liming Aero-engine Co. LTD.Shenyang 110000China

Presently,the service performance of new-generation high-tech equipment is directly affected by the manufacturing quality of complex thin-walled components.A high-efficiency and quality manufacturing of these complex thin-walled components creates a bottleneck that needs to be solved urgently in machinery *** address this problem,the collaborative manufacturing of structure shape and surface integrity has emerged as a new process that can shorten processing cycles,improve machining qualities,and reduce *** paper summarises the research status on the material removal mechanism,precision control of structure shape,machined surface integrity control and intelligent process control technology of complex thin-walled *** solutions and technical approaches are then put forward to solve the critical problems in the high-performance manufacturing of complex thin-wall *** development status,challenge and tendency of collaborative manufacturing technologies in the high-efficiency and quality manufacturing of complex thin-wall components is also discussed.

关键词： Collaborative manufacturing of shape and performance Complex thin-walled component Intelligent process control Material removal mechanism surface integrity

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Experimental study on surface integrity refactoring changes of Ti-17 under milling-ultrasonic rolling composite process

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Advances in Manufacturing 2023年第3期11卷 492-508页

作者： Zheng Zhou Chang-Feng Yao Liang Tan Ya Zhang Yi Fan Key Laboratory of High Performance Manufacturing for Aero Engine Ministry of Industry and Information TechnologySchool of Mechanical EngineeringNorthwestern Polytechnical UniversityXi'an 710072People's Republic of China Engineering Research Center of Advanced Manufacturing Technology for Aero Engine Ministry of EducationSchool of Mechanical EngineeringNorthwestern Polytechnical UniversityXi'an 710072People's Republic of China

Ultrasonic rolling is an advanced non-cutting surface strengthening method that combines traditional rolling with ultrasonic *** this research,the experiment of orthogonal end milling-ultrasonic rolling composite process has been carried *** surface integrity refactoring changes and its mechanism of Ti-17 titanium alloy during the milling-ultrasonic rolling composite process has been studied and analyzed by the test and analysis of the surface geometric characteristics,residual stress,microhardness and microstructure before and after ultrasonic *** residual stress and microhardness gradient distribution were characterized by cosine decay function and exponential decay *** indicators of surface integrity were significantly improved after ultrasonic *** study demonstrates that the reduction effect of the surface roughness by ultrasonic rolling process is inversely proportional to the initial surface roughness *** ultrasonic rolling can only change the distribution form of the surface topography when the initial surface roughness is *** addition,the improvement effect of ultrasonic rolling on surface compressive residual stress and microhardness decreased with the increase of initial milled surface roughness and surface compressive residual stress due to the factors such as energy absorption efficiency and mechanical properties changes of surface materials.A better ultrasonic rolled surface can be obtained by controlling the roughness and residual compressive stress of the initial milling surface to a small level.

关键词： Ti-17 End milling Ultrasonic rolling surface integrity Refactoring changes

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surface integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting

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Chinese Journal of Mechanical Engineering 2021年第4期34卷 42-55页

作者： Sai Guo Wei Du Qinghong Jiang Zhigang Dong Bi Zhang Department of Mechanical and Energy Engineering Southern University of Science and TechnologyShenzhen 518055China School of Mechanical Engineering Dalian University of TechnologyDalian 116024China Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education Dalian University of TechnologyDalian 116024China

The Ti6Al4V parts produced by the existing selective laser melting(SLM)are mainly confronted with poor surface finish and inevitable interior defects,which substantially deteriorates the mechanical properties and performances of the *** this regard,ultrasonically-assisted machining(UAM)technique is commonly introduced to improve the machining quality due to its merits in increasing tool life and reducing cutting ***,most of the previous studies focus on the performance of UAM with ultrasonic vibrations applied in the tangential and feed directions,whereas few of them on the impact of ultrasonic vibration along the vertical *** this study,the effects of feed rate on surface integrity in ultrasonically-assisted vertical milling(UAVM)of the Ti6Al4V alloy manufactured by SLM were systemically investigated compared with the conventional machining(CM)*** results revealed that the milling forces in UAVM showed a lower amplitude than that in CM due to the intermittent cutting *** surface roughness values of the parts produced by UAVM were generally greater than that by CM owing to the extra sinusoidal vibration textures induced by the milling ***,the extra vertical ultrasonic vibration in UAVM was beneficial to suppressing machining *** feed rate increased,surface microhardness and thickness of the plastic deformation zone in CM raised due to more intensive plastic deformation,while these two material properties in UAVM were reduced owing to the mitigated impact effect by the high-frequency vibration of the milling ***,the improved surface microhardness and reduced thickness of the subsurface deformation layer in UAVM were ascribed to the vertical high-frequency impact of the milling cutter in *** general,the results of this study provided an in-depth understanding in UAVM of Ti6Al4V parts manufactured by SLM.

关键词： Ultrasonically-assisted vertical milling surface integrity Ti6Al4V Selective laser melting

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