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Milling or grinding for manufacturing of an Alloy 718 gas turbine component?: - A comparison of surface integrity and productivity
RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.ORCID iD: 0000-0003-2991-2911
RISE Research Institutes of Sweden, Materials and Production, Manufacturing Processes.ORCID iD: 0000-0003-3656-1806
GKN Aerospace Engine Systems AB, Sweden.
Hanza Mechanics Sweden AB, Sweden.
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2024 (English)In: Procedia CIRP, E-ISSN 2212-8271, Vol. 123, p. 7-12Article in journal (Refereed) Published
Abstract [en]

Milling is traditionally the most used machining method when manufacturing complex gas turbine components. In particular those made from nickel-based superalloys. However, for larger free form surfaces, grinding may be an efficient alternative that could be used throughout the complete manufacturing route, from roughing to finishing. Hence, in this work the two processing methods has been compared in regard to surface integrity and productivity. Machining tests have been performed on case plates of heat-treated Alloy 718 using best practise setting for roughing and finishing with grinding and milling. The surface integrity of the work pieces was evaluated regarding surface topography, residual stresses, and deformation. This comparison showed that the main advantage with grinding is the ability to switch between roughing and finishing by just altering the depth of cut. Further, grinding offers lower surface roughness, compressive residual stresses, and significantly lower degree of deformation. From a productivity perspective, deep grinding may offer high material removal rates and ability to machine several work pieces in the same setup. However, grinding is limited to simpler free form geometries and may result in minor surface damages and abrasive surface residue. For selection of machining strategy, advantages and drawbacks shown in this work need to be considered for the application at hand in respect to productivity, surface integrity and requirements on fatigue life. 

Place, publisher, year, edition, pages
Elsevier B.V. , 2024. Vol. 123, p. 7-12
Keywords [en]
Finishing; Gas turbines; Milling (machining); Nickel alloys; Residual stresses; Surface roughness; Topography; Alloy 718; Free-form surface; Gas turbine components; Machining methods; Manufacturing complex; Milling; Nickel-based superalloys; Roughing and finishing; Surface integrity; Surface productivity; Grinding (machining)
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:ri:diva-74906DOI: 10.1016/j.procir.2024.05.004Scopus ID: 2-s2.0-85196790521OAI: oai:DiVA.org:ri-74906DiVA, id: diva2:1890452
Conference
7th CIRP Conference on Surface Integrity, CSI 2024. Bremen, Germany. 15 May 2024 through 17 May 2024
Note

The authors acknowledge VINNOVA for funding this work through the project GrindForm (ref. no. 2019-05833).

Available from: 2024-08-19 Created: 2024-08-19 Last updated: 2025-09-23Bibliographically approved

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Holmberg, JonasBerglund, Johan

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