Process Innovations: Emerging Trends in Grinding of Materials

Chicago, Illinois - 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 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 superabrasive 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 superabrasive 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.

About the speaker
K. Philip Varghese has worked for Saint-Gobain Abrasives since 2011, leading the Advanced Application Engineering Group at Higgins Grinding Technology Center in Northboro, MA. His group’s focus is 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 focused on dental product and materials evaluation. He has a PhD in Mechanical Engineering from University of Utah and an M.S. in Mechanical Engineering from University of Michigan, Ann Arbor. He has authored over 23 papers and articles in the field of machining, dental products/materials and grinding technology.

Registration for the IMTS 2016 Conferences is open now!