Experimental And Simulation Research On High Speed Turning Nickel-based Superalloy With PCBN Cutting Tools

Nickel-based superalloy, has become an important structural materials for aerospace andother strategic industries because of its excellent thermal performance and stability. But it’sone of the hardest materials to machine due to its poor machinability. With the rapiddevelopment of domestic aviation and aerospace industry, which lead to the contradictionbetween Nickel-base superalloy widely market demand at present and backward processingtechnology increasingly prominent. It’s one of the effective ways to machine difficult-to-cutmaterials using high speed cutting technology and new material tool in the current.Polycrystalline Cubic Boron Nitride (PCBN) tools performance excellently in machiningdifficult-to-cut materials like nickel-based superalloy because of its high hardness and goodchemical stability. But it hasn’t used universally in practice due to its high costs. In order topromote manufacturing efficiency and economy of nickel based superalloy，the principles ofthe theory of metal cutting techniques, finite element simulation, experimental design andresearch and numerical analysis were adopted to study high speed turning nickel-basedsuperalloy GH4169with PCBN tools，explored the effects of cutting parameters and toolgeometric parameters on machinability. Specific researches are as follows:1) Research on prediction model of cutting forces. Nickel-based superalloy GH4169highspeed turning with PCBN tools was carried out based on orthogonal experimental method.The effect degrees and laws of cutting parameters on cutting forces were explored by rangeanalysis and analysis of variance. Empirical equation prediction model of cutting forces wereestablished by multiple linear regression with least squares estimation, and the validity of themodels was examined by significant tests.2) Study on surface roughness. The basic rules of cutting parameters on surfaceroughness in nickel-based superalloy GH4169high speed turning with PCBN tools werestudied by orthogonal experiment. Then, further study was carried out by response surfacemethod (RSM), second-order response model of surface roughness was established. Study ofinteraction of cutting parameters was taken. Based on RSM, a cutting parameters optimalselection method including material removal rate was proposed.3) Research on simulation of cutting parameters. According to the experimental studies,three-dimensional finite element simulation model of nickel-based superalloy GH4169highspeed turning was established by using Deform-3D. Cutting process was simulated and thevalidity was demonstrated by cutting forces experiments. The effects of cutting parameters on cutting force and cutting temperature were studied by single factor experiment method.Stresses fields were also studied during high speed cutting GH4169.4) Simulation study of tool geometric parameters. Simulation analysis of PCBN Toolgeometrical parameters in nickel-based superalloy high Speed turning was performed byusing Deform-2D FEM software. The effect laws of tool rake angle and corner radial oncutting forces, effective stress, cutting temperature etc. were studied by FEM.Summing up the above, the study works in this paper has laid the solid theoreticalfoundation for the research on machining mechanism and process theory in high speed cuttingnickel-based superalloy using PCBN tools, accelerated application of PCBN and other newkind of tools and enhanced Nickel-based superalloy manufacturing level.