Study On Cutting Force And Tool Wear Of Superalloy Under High Pressure Cooling

As an important material of key components in aerospace,shipbuilding,atomic energy and vehicle industry,superalloy plays an important role in national manufacturing industry.With the rapid development of China's manufacturing industry,the demand of superalloy has gradually improved.But the difficult machinability of superalloy is the difficulty in manufacturing,which is characterized with high cutting force,serious tool wear,high temperature and so on.In order to solve the above problems,using high pressure cooling is an effective way and can improve the machining effect.Through the experiment of PCBN tools cutting nickel-based superalloy under high pressure cooling,the present paper explores ideal solution to improve cutting quality and efficiency of superalloy by analyzing the law of cutting force and tool wear.Firstly,mathematical model of cutting force under high pressure cooling is established.According to the right angle cutting theory,simplifying the calculation of relevant parameters in oblique cutting process and establishing oblique model of cutting force coefficient.Based on the study of high pressure cooling theory and cooling lubrication process,the reasons of cutting force variation and calculation method of friction coefficien under high pressure cooling are discussed.Combining with conventional cutting force model,construction of cutting force coefficient model under high pressure cooling is completed.Support of cutting force prediction and tool wear analysis under high pressure cooling can be provided.Secondly,finite element simulation analyses of turning process under high pressure cooling and PCBN tool wear process are made.Simulation of turning process is done by Third Wave Advant Edge software.Based on the simulation of cutting force,the variation regularities of cutting force under high pressure cooling are analyzed and forecasted.The simulation of the tool wear process is done by DEFORM software,gradual process of tool wear is analysed,reference for the studyof tool wear morphology can be provided.Thirdly,experiment of cutting nickel-based superalloy under high pressure cooling is done.According to the test results,the relationships between cooling conditions,cutting parameters and cutting force are analyzed.The cutting force coefficient model under high pressure cooling is improved and modified,and the cutting force empirical model is established.The models are verified and provide support for cutting parameter optimization.Multi-objective optimization model of cutting parameters is established.Cutting parameters are optimized by using genetic algorithm and combining results of experiment.Finally,tool wear condition of PCBN under high pressure cooling is studied.On the basis of tool wear test and analyzing tool wear morphology,the tool failure reasons of PCBN are discussed.The influence of cutting conditions on tool wear is studied.The tool wear law under high pressure cooling is obtained.Combining with the test results of cutting force,the selection of cutting parameters considering tool wear under high pressure cooling is analyzed.Advice and reference for improving tool life and machining efficiency can be provided.