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An Exploration of Surface Integrity Remanufacturing for Aeroengine Components

Qiao Xiang,Yong He,Ting-hong Hou

《工程管理前沿（英文）》 2016年 第3卷 第2期   页码 107-114 doi: 10.15302/J-FEM-2016025

摘要： Surface integrity is the major factor impacting on the operation quality, service life and reliability of the aeroengine components. The surface integrity of aeroengine component is damaged by the failures such as crack, deformation, oxidation, corrosion, erosion, and microstructural degeneration. It adopts advanced remanufacturing technologies to restore or improve the surface integrity and regenerate these high value parts. This paper firstly puts forward the concept, namely surface integrity remanufacturing for aeroengine components, and its connotation. The key remanufacturing technologies have been developed to repair the components with surface damages. Ultimately, some application examples of surface integrity remanufacturing technologies as well as their effects in aeroengine maintenance are introduced. The discarded components have been reused and their service lives have been extended and their reliability has been increased by implementing surface integrity remanufacturing. It has realized “The Repaired Components Outpacing the New Ones”, material saving, energy saving, and emission reduction.

关键词： aeroengine component     surface integrity     remanufacturing     surface integrity remanufacturing    

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Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

Tao SUN, Lufang QIN, Junming HOU, Yucan FU

《机械工程前沿（英文）》 2020年 第15卷 第3期   页码 504-515 doi: 10.1007/s11465-020-0586-2

摘要： The damage-tolerant titanium alloy TC21 is used extensively in important parts of advanced aircraft because of its high strength and durability. However, cutting TC21 entails problems, such as high cutting temperature, high tool tip stress, rapid tool wear, and difficulty guaranteeing processing quality. Orthogonal turn-milling can be used to solve these problems. In this study, the machinability of TC21 in orthogonal turn-milling is investigated experimentally to optimize the cutting parameters of orthogonal turn-milling and improve the machining efficiency, tool life, and machining quality of TC21. The mechanism of the effect of turn-milling parameters on tool life is discussed, the relationship between each parameter and tool life is analyzed, and the failure process of a TiAlN-coated tool in turn-milling is explored. Experiments are conducted on the integrity of the machined surface (surface roughness, metallographic structure, and work hardening) by turn-milling, and how the parameters influence such integrity is analyzed. Then, reasonable cutting parameters for TC21 in orthogonal turn-milling are recommended. This study provides strong guidance for exploring the machinability of difficult-to-cut-materials in orthogonal turn-milling and improves the applicability of orthogonal turn-milling for such materials.

关键词： orthogonal turn-milling     damage-tolerant titanium alloy     tool life and failure     machined surface integrity     machinability    

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Predictive model to decouple the contributions of friction and plastic deformation to machined surface

Subhash ANURAG, Yuebin GUO,

《机械工程前沿（英文）》 2010年 第5卷 第3期   页码 247-255 doi: 10.1007/s11465-010-0097-7

摘要： Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement. Furthermore, the individual contribution of tool/work friction and plastic deformation of work materials to surface temperature is very difficult to quantify because the measured temperature is always the resultant temperature. This lack of understanding on the temperature distribution blocks the design of effective cutting tool geometries and materials to minimize surface temperature. This study provides a finite element method based on a predictive model to decouple the contributions of tool/work friction and material plastic deformation to surface temperature in a dry cutting process. The study shows that the plastic deformation of work material contributes to the majority of surface temperature, whereas the tool/work friction contribution is secondary. High temperatures are produced when more materials are plowed under the cutting edge. A large tool/work friction leads to higher surface temperatures, and the use of a cutting tool with physical properties in process simulation significantly improves the accuracy of predicted surface temperatures. Residual stress reversal from subsurface maximum residual to surface maximum residual stress may occur when tool/work friction increases.

关键词： surface temperature     friction     residual stress     finite element analysis (FEA)     dry cutting     tool property    

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Experimental study of surface integrity and fatigue life in the face milling of Inconel 718

Xiangyu WANG, Chuanzhen HUANG, Bin ZOU, Guoliang LIU, Hongtao ZHU, Jun WANG

《机械工程前沿（英文）》 2018年 第13卷 第2期   页码 243-250 doi: 10.1007/s11465-018-0479-9

摘要：

The Inconel 718 alloy is widely used in the aerospace and power industries. The machining-induced surface integrity and fatigue life of this material are important factors for consideration due to high reliability and safety requirements. In this work, the milling of Inconel 718 was conducted at different cutting speeds and feed rates. Surface integrity and fatigue life were measured directly. The effects of cutting speed and feed rate on surface integrity and their further influences on fatigue life were analyzed. Within the chosen parameter range, the cutting speed barely affected the surface roughness, whereas the feed rate increased the surface roughness through the ideal residual height. The surface hardness increased as the cutting speed and feed rate increased. Tensile residual stress was observed on the machined surface, which showed improvement with the increasing feed rate. The cutting speed was not an influencing factor on fatigue life, but the feed rate affected fatigue life through the surface roughness. The high surface roughness resulting from the high feed rate could result in a high stress concentration factor and lead to a low fatigue life.

关键词： roughness     hardness     residual stress     microstructure     fatigue life    

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基于分形和小波的几何型面加工误差综合分析

廖小云,唐倩,赵英,郑世泽

《中国工程科学》 2002年 第4卷 第5期   页码 75-78

摘要：

对几何型面加工误差提出并建立了基于分形和小波的综合分析方法，可以精细分析几何型面加工误差的微细成分，并重构出型面轮廓加工误差曲线，以便进行公差与性能关系分析以及加工过程质量监控等相关工作。应用实例表明，该方法是非常有效的。

关键词： 机加工     加工误差分析     分形几何     小波分析    

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Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

《机械工程前沿（英文）》 2022年 第17卷 第2期 doi: 10.1007/s11465-022-0680-8

摘要： Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

关键词： milling     grinding     fiber-reinforced composites     damage formation mechanism     delamination     material removal mechanism     surface integrity     minimum quantity lubrication    

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高强度合金抗疲劳应用技术研究与发展

越振业

《中国工程科学》 2005年 第7卷 第3期   页码 90-94

摘要：

评述了超高强度钢、高强度A1合金和Ti合金表面完整性抗疲劳应用技术的研究和发展。高强度合金疲劳性能对应力集中敏感，不适当的加工工艺和切削热等造成的表面损伤和髙拉应力使其疲劳和应力腐蚀性能损失殆尽。先进的表面完整性加工尤其是表面改性可显著提高疲劳性能，如激光冲击使7475-T761拉-拉疲劳寿命提高约89%，7075-T6裂纹扩展速率降低到原来的1/1500;超声喷丸使超高强度钢低周疲劳强度提高约50%，Ti7A14Mo合金髙周疲劳强度提高约15%;表面超硬化可使Vasco X-2M齿轮钢接触疲劳寿命提高30～35倍等。

关键词： 高强度合金     表面完整性     激光冲击     表面超硬化    

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表面完整性研究的进展与展望

房丰洲, 顾春阳, 郝然, 游开元, 黄思雨

《工程（英文）》 2018年 第4卷 第6期   页码 754-758 doi: 10.1016/j.eng.2018.11.005

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Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0730-2

摘要： Ultrasonic vibration-assisted grinding (UVAG) is an advanced hybrid process for the precision machining of difficult-to-cut materials. The resonator is a critical part of the UVAG system. Its performance considerably influences the vibration amplitude and resonant frequency. In this work, a novel perforated ultrasonic vibration platform resonator was developed for UVAG. The holes were evenly arranged at the top and side surfaces of the vibration platform to improve the vibration characteristics. A modified apparent elasticity method (AEM) was proposed to reveal the influence of holes on the vibration mode. The performance of the vibration platform was evaluated by the vibration tests and UVAG experiments of particulate-reinforced titanium matrix composites. Results indicate that the reasonable distribution of holes helps improve the resonant frequency and vibration mode. The modified AEM, the finite element method, and the vibration tests show a high degree of consistency for developing the perforated ultrasonic vibration platform with a maximum frequency error of 3%. The employment of ultrasonic vibration reduces the grinding force by 36% at most, thereby decreasing the machined surface defects, such as voids, cracks, and burnout.

关键词： ultrasonic vibration-assisted grinding     perforated ultrasonic vibration platform     vibration characteristics     apparent elasticity method     grinding force     surface integrity    

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Local fracture properties and dissimilar weld integrity in nuclear power plants

Guozhen WANG, Haitao WANG, Fuzhen XUAN, Shantung TU, Changjun LIU

《机械工程前沿（英文）》 2013年 第8卷 第3期   页码 283-290 doi: 10.1007/s11465-013-0250-1

摘要：

In this paper, the local fracture properties in a Alloy52M dissimilar metal welded joint (DMWJ) between A508 ferritic steel and 316 L stainless steel in nuclear power plants were investigated by using the single-edge notched bend (SENB) specimens, and their use in integrity assessment of DMWJ structures was analyzed. The results show that the local fracture resistance in the DMWJ is determined by local fracture mechanism, and which is mainly related to the microstructures and local strength mismatches of materials at the crack locations. The initial cracks always grow towards the materials with lower strength, and the crack path deviation is mainly controlled by the local strength mismatch. If the local fracture properties could not be used for cracks in the heat affected zones (HAZs), interface and near interface zones, the use of the fracture properties ( -resistance curves) of base metals or weld metals following present codes will unavoidably produce non-conservative (unsafe) or excessive conservative assessment results. In most cases, the assessment results will be potentially unsafe. Therefore, it is recommended to obtain and use local mechanical and fracture properties in the integrity assessment of DMWJs.

关键词： local fracture properties     dissimilar metal welded joint     integrity assessment     strength mismatch     crack growth path    

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Emerging challenges to structural integrity technology for high-temperature applications

TU Shantung

《机械工程前沿（英文）》 2007年 第2卷 第4期   页码 375-387 doi: 10.1007/s11465-007-0066-y

摘要： Structural integrity technology has been widely used with great success for the design, manufacture and failure prevention of modern constructions such as chemical and petrochemical plants, power generation and energy conversion systems, as well as space and oceanic exploration. The modern needs of structural integrity technology are largely attributed to the increase of service temperature of the structures that results in the efficiency improvement in energy conversion and chemical processing technologies. Besides the needs arising from large-scale high-temperature plants, the high tech developments, such as micro chemo-mechanical systems and high-power electronics, provide new challenges to structural integrity technology. The present paper summarizes the recent technical progresses in large process plants and the aviation industry, micro chemo-mechanical systems, fuel cells, high-temperature electronics, and packaging and coating technologies. The state-of-the-art of structural integrity technology for high temperature applications is reviewed. Suggestions are provided for the improvement of current design and assessment methods.

关键词： manufacture     aviation industry     conversion     petrochemical     temperature    

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Recent development in low-constraint fracture toughness testing for structural integrity assessment of

Jidong KANG, James A. GIANETTO, William R. TYSON

《机械工程前沿（英文）》 2018年 第13卷 第4期   页码 546-553 doi: 10.1007/s11465-018-0501-2

摘要：

Fracture toughness measurement is an integral part of structural integrity assessment of pipelines. Traditionally, a single-edge-notched bend (SE(B)) specimen with a deep crack is recommended in many existing pipeline structural integrity assessment procedures. Such a test provides high constraint and therefore conservative fracture toughness results. However, for girth welds in service, defects are usually subjected to primarily tensile loading where the constraint is usually much lower than in the three-point bend case. Moreover, there is increasing use of strain-based design of pipelines that allows applied strains above yield. Low-constraint toughness tests represent more realistic loading conditions for girth weld defects, and the corresponding increased toughness can minimize unnecessary conservatism in assessments. In this review, we present recent developments in low-constraint fracture toughness testing, specifically using single-edge-notched tension specimens, SENT or SE(T). We focus our review on the test procedure development and automation, round-robin test results and some common concerns such as the effect of crack tip, crack size monitoring techniques, and testing at low temperatures. Examples are also given of the integration of fracture toughness data from SE(T) tests into structural integrity assessment.

关键词： fracture toughness     constraint effect     single-edge-notched tension test     pipeline     structural integrity assessment    

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How does the improved DB mode degrade the complex integrity of infrastructure mega-projects?

Jinwen ZHANG, Yumin QIU

《工程管理前沿（英文）》 2018年 第5卷 第1期   页码 40-51 doi: 10.15302/J-FEM-2018083

摘要： Complex integrity is one of the main characteristics of infrastructure mega-projects (IMPs). Cost, technology, risk, duration, environmental impact, and other uncertain complexities are interrelated and constitute a challenging and complex management problem. At present, there is no unified understanding of or solutions to these complex integrity problems. This study analyzes the complex integrity of the island-tunnel subproject of the Hong Kong-Zhuhai-Macao Bridge (HZMB) project and proposes an improved design-build (DB) mode in which the owner provides a preliminary design and has the right to form and manage consortium. This improved DB mode creatively degrades the special complexities that arise from multiple dimensions. On this basis, it is an efficacious way to grasp the main contradictions, integrate the effective resources, and degrade the complex integrity in multiple dimensions and at multiple levels so as to effectively deal with the complexity management of IMPs.

关键词： Hong Kong-Zhuhai-Macao Bridge project     island-tunnel subproject     complex integrity     complexity degradation     the general contracting mode of design-build     the design-build consortium    

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一种超高强度钢构件抗疲劳实验研究

赵振业,宋德玉,李向斌,杨树勋,马新闻

《中国工程科学》 2005年 第7卷 第10期   页码 51-55

摘要：

提出了超高强度钢“无应力集中”抗疲劳概念。喷丸、孔挤压、螺纹滚压等表面层组织再造改性造成的残余压应力和高位错密度胞状结构将裂纹推移至亚表面萌生并阻滞其扩展，回复不同应力集中处的疲劳强度至接近钢的固有疲劳强度，形成“无应力集中”表面完整性状态。“无应力集中”抗疲劳概念表述为构件表面形成完整的接近于钢固有疲劳强度的等疲劳强度包络。

关键词： 超高强度钢     抗疲劳     应力集中     表面完整性    

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Propagation characteristics of transient waves in low-strain integrity testing on cast-in-situ concrete

Hanlong LIU, Xuanming DING

《结构与土木工程前沿（英文）》 2009年 第3卷 第2期   页码 240-240 doi: 10.1007/s11709-009-0100-8

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标题 作者 时间 类型 操作

An Exploration of Surface Integrity Remanufacturing for Aeroengine Components

Qiao Xiang,Yong He,Ting-hong Hou

期刊论文

Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

Tao SUN, Lufang QIN, Junming HOU, Yucan FU

期刊论文

Predictive model to decouple the contributions of friction and plastic deformation to machined surface

Subhash ANURAG, Yuebin GUO,

期刊论文

Experimental study of surface integrity and fatigue life in the face milling of Inconel 718

Xiangyu WANG, Chuanzhen HUANG, Bin ZOU, Guoliang LIU, Hongtao ZHU, Jun WANG

期刊论文

基于分形和小波的几何型面加工误差综合分析

廖小云,唐倩,赵英,郑世泽

期刊论文

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

期刊论文

高强度合金抗疲劳应用技术研究与发展

越振业

期刊论文

表面完整性研究的进展与展望

房丰洲, 顾春阳, 郝然, 游开元, 黄思雨

期刊论文

Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites

期刊论文

Local fracture properties and dissimilar weld integrity in nuclear power plants

Guozhen WANG, Haitao WANG, Fuzhen XUAN, Shantung TU, Changjun LIU

期刊论文

Emerging challenges to structural integrity technology for high-temperature applications

TU Shantung

期刊论文

Recent development in low-constraint fracture toughness testing for structural integrity assessment of

Jidong KANG, James A. GIANETTO, William R. TYSON

期刊论文

How does the improved DB mode degrade the complex integrity of infrastructure mega-projects?

Jinwen ZHANG, Yumin QIU

期刊论文

一种超高强度钢构件抗疲劳实验研究

赵振业,宋德玉,李向斌,杨树勋,马新闻

期刊论文

Propagation characteristics of transient waves in low-strain integrity testing on cast-in-situ concrete

Hanlong LIU, Xuanming DING

期刊论文