Burr formation mechanism and morphological transformation in grinding of nickel-based superalloy honeycomb cores under ice freezing and MQL conditions

Nickel-based superalloy honeycomb core (NBSHC) is extensively used in aerospace field due to the light weight, high specific strength and high temperature resistance. The burrs of NBSHC are extremely prone to be formed during machining and the insufficient welding strength or false welding between NBSHC and skin is generated because of the large or unreasonable burr morphology, resulting in premature failure of the parts. In this work, a novel method of ice freezing combining with minimum quantity lubrication (MQL) was proposed to grind NBSHC to improve the burr morphology and size. The burr formation mechanisms of NBSHC under ice freezing and MQL conditions were revealed by single abrasive particle grinding cell wall and verified by grinding experiments. The grinding force, burr morphology transformation mechanisms and size were investigated in-detail by experiments combining with FEM results. The results indicated that MQL and ice freezing decreased the plastic flow property of material by reducing the temperature and friction of NBSHC, thereby promoting the transformation of burr size from large into micro, and the burr shape from long strip into block. Decreasing grinding depth can also improve the burr morphology by decreasing the volume of plastic flow material. The improving effects of full of ice freezing were better than MQL for NBSHC grinding. The machining efficiency under full of ice combining with MQL was 3 times of that under quasi-dry grinding. These findings are significant for improving the machining quality and exploring the burr morphology transformation of NBSHC.