Research On Cutting Performance And Anti-wear Mechanism Of Tools With Micro-texture Under Spray Cooling

Nickel-based superalloy GH4169 is a difficult-to-machine material with high hardness,high strength,corrosion resistance and high temperature resistance,and the ordinary tools often have some machining problems such as severe tool wear,rapid failure and short life in turning.Surface micro-texture has proven to be an effective measure to improve the friction properties of materials and improve surface carrying capacity.In recent years,micro-texture has been gradually applied to the field of metal cutting,and the introduction of micro-texture has greatly improved the cutting performance and wear condition of the tool.In this paper,the anti-friction effect of micro-texture was applied to the cutting research of the nickel-based superalloy.Under the condition of the spray cooling auxiliary processing,some tools with micro-texture of different morphologies were used to carry out the experiment of turning GH4169.The cutting performance and anti-wear mechanism of the micro-texture tool were analyzed.The specific research content are as follows:Firstly,several groups of pit micro-textures with different size parameters were designed in this paper,and the Deform analysis software was used to establish a 3D simulation model of micro-texture tool turning GH4169.This model simulates the cutting process of each group of micro-texture tools respectively.The effect of the distance between the micro-texture and the cutting edge,the diameter of micro-pits and the spacing of micro-pits on the cutting force and the action law were analyzed,and the size parameters of the micro-texture with a significant reduction on cutting force were preferred.Secondly,the designed micro-textures were processed by the femtosecond laser processing technology on the rake face of the carbide tools.Under the condition of the spray cooling,GH4169 was turned by the carbide tools with micro-texture of different size parameter.The influence of micro-texture with different size parameters on cutting force was analyzed,and the accuracy of the simulation model established was verified.Thirdly,the ultra depth of field electron microscopy system was used to measure the wear area of the rake face of the tools for cutting experiments.The wear area of the rake face was estimated using the micro-element method and compared with the wear of the rake face of the non-texture tool.The effect of the size parameters of the micro-texture on the wear of the rake face of tool was analyzed,and the size parameters of the micro-texture with good anti-wear effect were obtained.In addition,the micro-wear morphology of the rake face was photographed by the electron microscope scanner,and the surface components of the tool before and after the experiment were analyzed qualitatively and quantitatively.Combined with the theoretical knowledge of tool wear,the wear mechanism of tools on the rake face and flank face after cuting GH4169 were analyzed.Finally,a comparative experiment of spray cooling and dry cutting of GH4169 was performed to analyze the effect of spray cooling on the anti-wear of pit micro-texture.The finite element analysis software Abaqus was used to establish a friction model of pit micro-texture to analyze the friction characteristics between the friction pairs with surface micro-texture.Based on the cutting simulation model established by Deform,the finite element analysis of the stress distribution and temperature distribution on the rake face of the pit micro-texture tool in the cutting process was made.Based on several aspects,the anti-wear mechanism of the micro-texture tool under spray cooling was studied,which provides guidance for the design and development of the micro-texture tool.