Simulation And Experimental Study Of Tool Wear In GH4169 Cutting Process Based On FEM

Nickel based superalloy has high strength,good stability and fatigue resistance at high temperature of 600? or above.So it is commonly used in ring shaft parts of aero engines as structural materials.In the cutting process of nickel based superalloy,the poor thermal conductivity and the high tendency of work-hardening,which severly affects the tool life,the quality of machined surfaces,the machining cost and efficiency.So the study of wear rules and morphology of coated carbide tools used for cutting nickel based superalloy that has great significance for the actual machining of ring shaft parts of aero engine.A precise MJ groove cemented carbide tool and the worn tools with different wear degree were established based on UG NX8.5.Combined with the key technologies of finite element simulation contained material constitutive model,separation criterion,meshing technique,the three-dimensional finite element simulation thermal-mechanical coupling model of GH4169 alloy turning process was established based on the finite element simulation software DEFORM-3D.The trend of cutting forces,the distribution of cutting temperature and tool wear were obtained by analysis of FEM.The influence of tool wear on cutting forces and cutting temperature were analyzed.Compared with the cutting forces and the crater wear morphology obtained from single factor experiments of turning GH4169 with cemented carbide tools,which were verified the simulation model.The changing rules of cutting forces,flank wear and chip shape were analyzed under different cutting parameters.The tool wear process under specific cutting parameter was analyzed,the tool life was determined,and the influence of tool wear on cutting forces were analyzed deeply.In order to optimize the geometric parameters and the groove shape of the cutting tool,a two-dimensional orthogonal finite element simulation thermal-mechanical coupling model of GH4169 alloy turning process wasestablished based on the finite element simulation software DEFORM-2D.The influence of tool?s rake angle,relief angle,cutting edge radius and groove shape on cutting forces,cutting temperature and tool wear were analyzed.Taking the minimum tool wear as the goal,the geometric parameters of the tool and the groove were optimized.It has guiding significances for tool design optimization of coated cemented carbide for cutting nickel based superalloy.The results of this research provide the theoretical basis and foundation for the control of tool wear and the optimization of structural design of coated carbide tools used for cutting nickel based superalloy.