Finite Element Analysis Of The Cutting Process And Tool Wear In Prestressed Cutting Of Nickel-based Superalloy

Nickel-based super-alloy material has been widely utilized in the aerospaceindustry for its outstanding performance, including high temperature strength, heatresistance, corrosion resistance, etc. The parts of this kind of material always work inthe bad environment, and bear complex alternating stress load and thermal load,Aiming at the problem that the part is easy to appear fatigue damage, the prestressedcutting method is proposed. Prestressed cutting method can control the compressiveresidual stress to a certain range and no work hardening phenomenon occur onmachined surface, then it improves the bearing ability of the part, and which isdifficult to achieve via other residual stress adjustment method. In this paper, basedon experiment research and finite element simulation in Abaqus/Explicit,theprestressed cutting process of Ni alloy, residual stress and tool wear are studied..Themajor works are included as follows:1、The state of the art in the research of cutting Ni alloy,tool wear and finiteelement simulation of cutting process are summarized.2、The relevant theories of finite element numerical simulation are reviewed, thecritical techniques in cutting simulation are researched, by use of, two dimensionfinite cutting models are established in ABAQUS/Explicit and ADVANTEDGEsoftwares respectively, the workpiece Mises stress,equivalent plastic strain and thedistribution of cutting temperature in the cutting process are simulated, theconstitutive model of Ni-based super-alloy in ABAQUS is established.3、Based on Usui′s wear rate model,Python language is adopted for secondarydevelopment of the post-processing part of the ABAQUS, calculation procedure of theamount of tool wear in the cutting process is compiled, the status of tool wear in thecutting process of nickel base superalloy is simulated.4、The finite element model of three-dimensional prestressed cutting process isestablished, the process of prestressed cutting nickel-based high-temperature alloyshaft is simulated,the influence of prestress on Mises stress,chip morphology, cuttingtemperature and equivalent plastic strain are analyzed; S11, S22and S33distributionis discussed under different prestressed state; the influence of prestress and cuttingparameters and tool materials on cutting force is studied.5、Pre-stressed cutting experiments of nickel-based super-alloy in the CA6140lathe are carried out; the characteristics and tool wear on the surface of the morphology are discussed, the effects law of cutting speed, cutting depth, cutting toolmaterials and pre-stress size on the tool flank wear is studied, and compared with thesimulation results, the finite element simulation model is verified.6、The main content of this thesis and the insufficiency are summarized, and thefurther research work is prospected.