Multi-scale modeling reveals microstructural and mechanical evolution in GH4169 and DD5 nickel-based superalloys during grinding

This study delves into the grinding-induced microstructural and mechanical evolution in high-entropy nickel-based superalloys GH4169 and DD5, underscoring their distinct behaviors under varying machining conditions. Leveraging “Random Substitution” in Material Studio, the research developed intricate atomic models to accurately depict the complex chemical compositions and microstructures of these superalloys. Neper software was employed for multi-scale modeling, specifically analyzing the unit cells of GH4169. A critical focus was placed on the effects of key grinding parameters—depth, spindle speed, and feed rate—on the crystallographic deformation of GH4169, contrasting it with the response of DD5. The study highlighted a notable transition in GH4169’s material removal mechanism from plastic flow to chip spallation at enhanced grinding depths and feed rates, while maintaining lattice integrity at higher grinding speeds. GH4169 consistently demonstrated greater tangential and normal forces during grinding compared to DD5, reflecting intricate machining complexities. The differential crystal orientations between these superalloys significantly impacted the grinding force distribution and heat dissipation during the process. This comprehensive analysis provides pivotal insights into the micro-level grinding process parameters, enriching both theoretical and practical understanding of material machinability in advanced manufacturing contexts. The study’s novelty lies in its application of detailed atomic models and multi-scale modeling to uncover subtle microstructural and mechanical dynamics during the grinding of superalloys.