SAE AMS 2453-2010 Low Stress Grinding of Steel Parts Heat Treated to 180 ksi or Over and Low Stress Grinding of Chrome Plating Applied to Steel Parts Heat Treated to 180 ksi or Ove.pdf

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1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report isentirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefr

2、om, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2015 SAE InternationalAll rights reserved. No part of this public

3、ation may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE.TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada)Tel: +1 724-776-4970 (outs

4、ide USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visithttp:/www.sae.org/technical/standards/AMS2453AEROSPACEMATERIAL SPECIFICATIONAMS2453Issued 2010-08Reaffirmed 2015-11Low Stress Grindi

5、ng of Steel Parts Heat Treated to 180 ksi or Over,and Low Stress Grinding of Chrome Plating Applied to Steel PartsHeat Treated to 180 ksi or OverRATIONALEAMS2453 has been reaffirmed to comply with the SAE five-year review policy.1. SCOPE 1.1 Purpose The purpose of this specification is to establish

6、requirements of a grinding method and to provide grinding parameters that will eliminate or minimize overheating, cracking, high residual tensile stresses, and/or other metallurgical changes that decrease structural integrity of steel parts or chrome plated steel parts (See 8.2). This standard estab

7、lishes requirements for low stress grinding of martensitic high strength steel heat-treated to 180 ksi (1241 MPa) minimum ultimate tensile strength (UTS) and above, and requirements for low stress grinding of chromium plating applied to such high strength steel.1.2 Application This process has been

8、used typically to grind chrome plating on high strength steel and high strength steel parts heat treated to 180 ksi (1241 MPa) ultimate tensile strength and above for applications requiring wear, heat, and corrosion resistance or dimensional restoration, such as aircraft landing gear and hydraulic a

9、ctuator components. However, usage is not limited to such applications (See 8.3). 1.3 Safety Hazardous Materials While the materials, methods, applications, and processes described or referenced in this specification may involve the use of hazardous materials, this specification does not address the

10、 hazards that may be involved in such use. It is the sole responsibility of the user to ensure familiarity with the safe and proper use of any hazardous materials and to take necessary precautionary measures to ensure the health and safety of all personnel involved. 2. APPLICABLE DOCUMENTS The issue

11、 of the following documents in effect on the date of the purchase order forms a part of this specification to the extent specified herein. The supplier may work to a subsequent revision of a document unless a specific document issue is specified. When the referenced document has been cancelled and n

12、o superseding document has been specified, the last published issue of that document shall apply. 2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.AMS2440 Ins

13、pection of Ground, Chromium Plated Steel Parts AMS2442 Magnetic Particle Acceptance Criteria for Parts AMS2644 Inspection Materials, Penetrant AMS2649 Etch Inspection of High Strength Steel Parts AMS2759, /1, /2, /9, /11 Heat Treatment of Steel Parts ARP4462 Barkhausen Noise Inspection for Detecting

14、 Grinding Burns in High Strength Steel Parts 2.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM E 1417 Liquid Penetrant Testing ASTM E 1444 Magnetic Particle Testing ASTM B 214 Sieve An

15、alysis of Metal Powders (See 8.5.7) 2.3 ANSI Publications Available from American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.ANSI B7.1 Safety Requirements for the Use, Care and Protection of Abrasive Wheels ANSI B74.13 Markings for Ide

16、ntifying Grinding Wheels and Other Bonded Abrasives 2.4 Department of Defense Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/.MIL-STD-867 Temper

17、 Etch Inspection 3. TECHNICAL REQUIREMENTS 3.1 Materials and Equipment 3.1.1 Materials 3.1.1.1 Cutting Fluids (Coolants) A suitable cutting fluid that does not have an adverse effect on the part being ground shall be used. SAE INTERNATIONAL AMS2453 Page 2 of 13_3.1.1.2 Grinding Wheels Grinding wheel

18、s shall be labeled with the complete grinding wheel specification including abrasive type, grit size, grade, structure, bond type, and maximum operating speed in accordance with ANSI B74.13. Unless otherwise specified, aluminum oxide vitrified bonded, grinding wheels shall be used. Care and protecti

19、on of grinding wheels, including proper storage, handling and mounting, shall be in accordance with ANSI B7.1. 3.1.2 Equipment 3.1.2.1 Grinding Equipment Grinding equipment shall be capable of maintaining grinding speed, work speed (spindle or traverse), cross feed and down feed in increments necess

20、ary to avoid surface degradation of the part. Provisions shall be made to supply a constant application of cutting fluid (coolant) to the working surface of the wheel at the grinding zone interface. Unless otherwise specified, a filter mesh size of 40 microns or better shall be used. A coolant nozzl

21、e sufficiently wide to flood the entire width of the grinding wheel shall be used. Unless otherwise specified, coolant supply equipment for grinding shall be capable of continuously supplying coolant to the work piece at a minimum rate of 2 gallons per minute per inch (4 liters per minute per 25.4 m

22、m) of wheel width. The equipment shall be capable of gravity separation of contaminants from coolant before recirculation, or a suitable continuous filter shall be provided to minimize recirculation of grinding residue and swarf. Coolant supply flow rates less than the minimum specified above shall

23、be acceptable for use provided the requirements of 3.4 are met. 3.1.2.2 Furnaces Furnaces (ovens) shall be controlled in accordance with AMS2759 as applicable when used for baking (/9) and stress relieving (/2 or /1 or /11). 3.2 Processing 3.2.1 Cleaning Protective coatings (other than chrome platin

24、g) and other foreign materials shall be removed from parts prior to grinding to preclude contamination of cutting fluids and wheels. Cutting fluids (coolant) and grinding residuals that have a deleterious effect on the part shall be removed after grinding. Cleaning materials shall not corrode or oth

25、erwise degrade the surface of the part. Where process delay time is such that corrosion might occur, parts shall be adequately protected after cleaning.3.2.2 Grinding Process Control 3.2.2.1 For a list of representative alloys that require low stress grinding see Table 1. Parts made from steels othe

26、r than those specified in Table 1, or parts heat treated to less than 180 ksi (i.e., AISI 4130 HT to 125 ksi (862 MPa) may be ground in accordance with the applicable requirements using processing parameters listed in Tables 2 or 3, or other processing parameters recommended by the material producer

27、, unless otherwise specified by purchaser. The grinding process shall be performed in accordance with Tables 2 or 3, as applicable, and Figure 1 or equivalent, to result in metallurgically sound parts. All feeds, speeds, and stock removal parameters are actual and not necessarily machine or indicato

28、r readings (See 8.4.5). Prior to grinding, clean all surfaces to be ground in accordance with 3.2.1. Prior to grinding, locate high spots on chrome plating in order to avoid accidental or excessive infeed during the grinding process. Caution should be exercised when grinding chrome plate since it is

29、 possible to cause damage in the substrate (See 8.2). Damage is difficult to detect through the chrome plate. SAE INTERNATIONAL AMS2453 Page 3 of 13_3.2.2.2 The processor shall maintain in-house documents designed to establish control of the grinding process and inspection procedures used (grinding

30、process control sheets, part-specific inspection technique sheets, etc.) to assure that parts produced are within acceptable design criteria. Grinding process control shall be documented and shall be used for processing of parts. Grinding Process Control Sheet (Figure 1) provides an example for proc

31、ess control documentation. The processor shall be able to demonstrate that they are applying such controls. In-house control documents are those documents used by each processor to control part configuration and quality. They include engineering drawings, engineering process specifications, process

32、orders, manufacturing process specifications, inspection procedures, grinding process control sheets, part-specific inspection technique sheets, and any other documents designed to control manufacturing and inspection techniques. Such documents are to be based upon proven techniques (See 3.4). 3.2.2

33、.3 Practices defined in this specification are not intended to restrict the processor from developing technology or methodology other than described herein provided the resulting part meets prescribed criteria (See 3.4) when approved by Cognizant Engineering Organization. 3.2.2.4 Balance the grindin

34、g wheel assembly at the time the wheel is mounted. If the grinding wheel remains on the machine arbor it will not need to be balanced again. If the grinding wheel is removed from the machine/arbor it shall be re-balanced at the next mounting. True the wheel face so that it is geometrically correct f

35、or the application and runs concentric with the centerline of the arbor assembly. 3.2.2.5 Flood the entire width of the grinding wheel at the wheel-work interface with a clean continuous flow of cutting fluid. Coolant concentration shall be maintained in accordance with the manufacturers instruction

36、s. A coolant nozzle sufficiently wide to flood the entire width of the grinding wheel shall be used. Unless otherwise specified, minimum cutting fluid flow rate shall be 2 gallons per minute per inch (7.6 liters per minute per 25.4 mm) of wheel width. Cutting fluid shall be liberally applied by floo

37、ding the wheel surface during all grinding passes, including the final “clean-up” or “spark out” passes. Never use a dry “spark out” pass during grinding of any heat treated steel or chromium plated steel surface. Coolant supply flow rates less than the minimum specified above shall be acceptable fo

38、r use provided the requirements of 3.4 are met. 3.2.2.6 Wheel Dressing Dress the grinding wheel as required during use to keep the wheel open with sharp grit exposed to freely cut the work material and to prevent grinding with a dull or “loaded” wheel that causes smearing or glazing of metal and gen

39、erates a large amount of frictional heat. Dress the wheel at a minimum frequency of 0.010 inch (0.254 mm) maximum of stock removal. Wheels should be dressed frequently and before the start of the final grinding passes to prevent grinding with a dull or loaded wheel. During grinding, constantly obser

40、ve cutting action of the abrasive wheels. Chatter, smearing, glazing, high part surface temperatures, excessive coolant vaporization, and higher than normal spindle amperage are good indications that grinding wheels require redressing (See 8.4.3).3.2.2.7 Wheel Speed During grinding operations, the p

41、rocessor shall not exceed the manufacturers maximum rated speed for any grinding wheel (refer to ANSI B7.1), or those in accordance with Tables 2 or 3, whichever is less (See 8.4.4). Some precipitation hardened alloys (e.g., Ferrium S53, AerMet 100, AerMet 310, AerMet 340, A-286, Custom 455, Custom

42、465, MLX-17, AF1410 and others, including the majority of PH stainless grades) may achieve high integrity ground surfaces using wheel speeds other than those listed in Tables 2 or 3 (e.g., 6500 SFPM) and shall be acceptable for use provided it does not exceed the manufacturers maximum rated speed fo

43、r the grinding wheel being used and the requirements of 3.4 are met. 3.2.2.8 Work Speed Work speeds shall be in accordance with Tables 2 or 3, as applicable. A rotating wheel (non-traversing) shall never contact a stationary part. SAE INTERNATIONAL AMS2453 Page 4 of 13_3.2.2.9 Down-feed/In-feed for

44、Plunge Grinding When plunge grinding, allowing each down-feed/in-feed of the grinding wheel to spark-out completely is required prior to applying next down-feed/in-feed increment. 3.2.2.10 Grinding With the Side of the Wheel Grinding of parts with the side of the wheel is prohibited unless authorize

45、d in writing by the cognizant engineering organization (See 8.4.7). When grinding with the side of the wheel is authorized, coolant application requirements per 3.2.2.5 shall be applied to the surface area of the side of the grinding wheel being used in contact with the workpiece. 3.3 Inspection Req

46、uirements and Procedures 3.3.1 Ground Surface Inspection All ground surfaces shall be visually inspected without magnification for evidence of overheating (discoloration), cracks, and tears. Ground surfaces shall be checked for surface finish. Specific surface finish requirements shall be specified

47、by the cognizant engineering organization. 3.3.2 Visual Inspection of Chromium Plate All ground chrome plate shall be visually examined for linear and mud cracking. Cracking in the chrome plate that can be seen with the unaided eye (corrected vision is acceptable) at a distance of 14 to 18 inches (3

48、56 to 457 mm) shall be cause for rejection. 3.3.3 Penetrant Inspection of Ground Chromium Plated Surfaces All ground chrome plated surfaces shall be inspected in accordance with AMS2440. 3.3.4 Rework of Rejected Ground Chrome Plate If the plated surface is rejected due to abusive grinding indications, the surface may be polished using 400 grit or finer silicon carbide abrasive paper, cloth, or aluminum oxide hone. The surface shall be p