Research On The Honing Technology Of Nickel-based Superalloy

Because of its good mechanical properties and thermal stability at high temperatures, Nickel-based superalloy is widely used in aerospace and other fields. And there are many hole parts in these fields, such as the compressor wheel hole, valve and bushing. The development of the times also puts forward new requirements for aircraft,such as greater thrust-weight ratio and higher speed, which is bound to the higher accuracy of the hole. However, nickel-based superalloy is a kind of typical difficult-to-machine material due to its low thermal conductivity, large plastic material, serious hardening. The existing finishing processes of nickel-based superalloy hole have many problems,such as unstable processing quality, unseasy to control processing precision.With both grinding and lapping characteristics, honing can provide a narrower geometric tolerance and low surface roughness. Honing has many advantages, such as high efficiency, stable machining quality, longer life of honing stone. But the current research on honing of nickel-based superalloy hole is not systematic and deep enough to guide the production practice. Therefore, research on the honing technology of nickel-based superalloy GH4169 is carried out in this paper, and the research results can provide technical support for the finish machining of GH4169 hole. The main work accomplished is as follows:(1) Orthogonal and single factor experiments of honing are carried out for GH4169 to analysis the influence of the process parameters on the material removal rate,(2) Material removal mechanism of honing is studied with simulation of single-grit honing based on DEFORM-3D combined with experiments.(3) Surface integrity is studied by Surface morphology, surface roughness, metallographic structure and micro-hardness to evaluate honing process of GH4169 synthetically; build prediction model of Rz after honing, and experimental verification error is less than 10%.(4) Shape accuracy of honing is studied, and the influence of the pre-cylindricity error to the cylindricity error is studied. The minimum margin and the maximum cylindricity tolerance prediction model of the bottom hole are set up, and the experimental verification error is less than 10%. Allowance is distributed for the hole with small allowance and a higher roughness request to achieve a higher efficiency.