Study on grinding material modification of nickel base single crystal superalloy by CEL method

To investigate material modifications in DD6 single-crystal superalloy during grinding, a three-dimensional finite element model (3D FEM) for single-grit grinding of DD6 was developed. To address challenges such as severe mesh distortion encountered in grinding simulations, the Couple + d Eulerian–Lagrangian (CEL) method was proposed and implemented. The influence of various grinding process parameters on surface integrity, as well as the variations in plastic deformation and residual stress within the surface and subsurface layers, were studied. The effectiveness of the simulation model was subsequently validated through experimental investigations. The results demonstrated that different grinding parameters led to the generation of distinct types of grinding chips, with the machined surface exhibiting varying degrees of damage. Grinding process parameters were found to significantly influence material modifications. The optimal process parameters were determined to be: wheel linear speed (vs) = 35 m/s, grinding depth (ap) = 20 μm, and feed rate (vw) = 0.6 m/min. This study offers new insights for predicting the grinding performance of DD6 alloy and optimizing grinding processes.