Efficient Cutting Technical Research Of The Difficult Cutting Material

Nickel-based superalloy GH4169 is a kind of metallic material that is widely used in rocket motor and aeronautic motor manufacturing. It is a kind of hard-to-cut material. The processing of nickle-based superalloy GH4169 has been the battle-neck of rocket development and manufacture as the result of the difficulties of cutting. In this paper, we have made systematic, theoretical and application researches. What have been done are as follows:First, an introduction was given for the background, significance and the status at home and abroad about high efficiency cutting technology of hard-to-cut material.After that, we designed a trial program to ascertain the parameters relating with GH4169 high efficiency cutting. This program includes test material, test equipment and the principles of processing and measuring.Then, we analyzed the processing features of tools used to cut nickel-based superalloy, and the material of tools used in the test as well as the structure.Researches have been done in this paper based on the results of the tests. In the tests, we chose surface modification high-speed steel and super-hard high-speed steel tools, coated carbide and common carbide tools to cut GH4169 efficiently,. Then, by analyzing the data of milling force, we analyzed how the major factors such as milling rate, tooth feed rate, radial cut depth and axial cut depth affected the milling force; how the different milling parameters in the two states of cooling and dry cutting affected the milling force, and then an analysis was made about the factors. All of these researches are the basis to select milling parameters in the following tests of tool life.As for the test tools, after the milling force experimental analysis, we took a series of durability comparative tests. According to the tests, we analyzed the difference of durability as well as its reason between coated tools and common tools, dense teeth tools and rare teeth tools. We also took wear comparative tests by choosing surface modification high-speed steel, super-hard high-speed steel tools, and then analyzed their wear mechanism. Finally, we have found out the high-speed steel tools that are more suitable to process nickel-based superalloys. In fact, it is quite basic for us to optimize the milling parameters in the next step.In this paper, based on the analysis to the tests, we have optimized the cutting process of nickel-based superalloys. And, finally we got the optimal cutting speed, following the two principles: total processing time and material removal amount within tool life.Based on all the results of the tests, we evaluated the tools used in the tests synthetically, and analyzed the material and structure of tools. Then, selected the carbide and high-speed steel tool material, structure and milling parameters to cut GH4169 with high efficiency. Applications have been made in many types based on our researches, which has improved production efficiency and made high social benefits.