Process Innovations - Saint-Gobain

2018 IIC Conference - Presentations

July 26, 2016

Monday, 9/12

2:15 to 3:10 p.m. / W-192-B

Session Topic: Emerging Trends in Grinding of Materials

Many aerospace components used in the high and low pressure sections of a turbine engine are made from materials such as high nickel-based super alloys and or intermetallics, such as gamma titanium aluminide. These sections that may be cast, forged, or sintered using powder metallurgy techniques are notorious for being difficult to machine due to their high strength, corrosion and fatigue resistance, and low thermal conductivity. Many of these components have as much as two-thirds of their original weight to be removed to produce the finished component; with the use of turning, milling, and broaching processes traditionally work to remove most or all of the material. However, with the use of modern grinding wheels composed of engineered grains and high strength bond technology, it has been determined that for these materials grinding can, in many instances, remove the material more quickly and economically than turning or milling. This presentation will show data/results of the following tests done on grinding of these advanced aerospace engine materials such as gamma titanium aluminide and IN718.

  • Speed-stroke surface grinding of gamma titanium aluminide with both engineered ceramic wheels as well as single layer and multi-layer super abrasive wheels
  • Creep feed grinding of IN718 and gamma titanium aluminide with engineered ceramic wheels
  • Face grinding and slotting of IN718 disks with engineered ceramic wheels and single layer super abrasive wheels.
  • Fixed abrasive polishing of contoured IN718 parts with engineered abrasive belts for robotic turbine-blade-polishing applications.

Further, with the use of gear-boxes in modern aerospace engines, there also exists an opportunity for grinding of gears from solid blanks. The presentation will show the latest data on grinding of gears from solid using grinding wheels with engineered ceramic grain technology.

K. Philip Varghese, Ph.D.

Group Leader,
Advanced Application Engineering
Saint-Gobain Abrasives

Dr. Philip Varghese has worked for Saint-Gobain Abrasives since 2011, leading the Advanced Application Engineering Group in Northboro, Massachusetts, focusing on providing grinding system solutions to abrasive customers, and the education and training of people in grinding science & technology. Prior to this, he worked as chief scientific officer for CR Foundation leading a team of scientists and engineers focusing on dental product and materials evaluation. He has a Ph.D. in Mechanical Engineering from University of Utah and an M.S. in Mechanical Engineering from University of Michigan, Ann Arbor. He has authored 23 technical papers and articles in the field of machining, dental products/materials and grinding technology.

Saint-Gobain designs, manufactures, and distributes materials and solutions which are key ingredients in the well-being of each of us and the future of all. They can be found everywhere in our living places and our daily life: in buildings, transportation, infrastructure, and in many industrial applications. They provide comfort, performance and safety while addressing the challenges of sustainable construction, resource efficiency and climate change.

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