Research On Continuous Milling Mechanism Of Inconel718 Nickel-based Superalloy

Nickel-based superalloy Inconel718 has good stability,fatigue resistance,and high strength and hardness.It is widely used in large-scale ship manufacturing,aerospace industry,large-scale machinery manufacturing and other industries.However,high-temperature alloys will produce large cutting forces and excessively high cutting temperatures during the machining process,and the tools will be severely worn.Therefore,by studying the cutting mechanism and tool wear mechanism in the continuous milling process of high-temperature alloys,the processing efficiency can be effectively improved and the processing cost can be reduced.This article mainly carried out the following work:Established a physical simulation model for continuous milling of Inconel718nickel-based superalloy based on ABAQUS simulation software,and briefly explained the material's constitutive model,material-related parameters,mesh division technology,and interaction properties.The calculation of the cutting heat in the milling process is carried out,and the distribution of the cutting temperature on the workpiece and the tool during the milling process is analyzed.Several sets of milling simulation experiments were carried out,and the law of influence of process parameters on cutting force and cutting temperature was obtained.Based on the multiple linear regression method,the empirical formula of the cutting force and cutting temperature prediction model was established,and the significance of the prediction model was verified by the residual analysis method;the prediction model of the tool wear was established based on the Archard tool wear theory.Designed an actual orthogonal cutting test to verify the accuracy of the cutting force,cutting temperature,and tool wear prediction model.Established the calculation formulas for the impact deflection,impact frequency and impact strength of the chip burr on the tool,and calculated the impact strength and impact frequency of the chip burr on the tool according to the actual cutting test.The formation causes of different tool wear morphologies and the tool wear mechanism are analyzed.Finally,it is concluded that the main wear mechanism of cemented carbide tools when milling superalloys is bond wear.The mathematical analysis method was used to construct the model formulas of the shear velocity field,the shear strain field and the shear strain rate field in the main shear zone,and the influence of the cutting speed and the tool rake angle on the shear velocity,shear strain and shear strain rate was analyzed.Through the analysis of the reason and mechanism of chip formation in the milling process,it is finally concluded that the chip shape in the milling process is mainly serrated.Through the combination of theory and experiment,the relationship between cutting force,chip morphology and surface quality is analyzed,and finally it is concluded that as the cutting force increases,the sawtooth of the chips becomes more and more serious,and the surface roughness of the machined surface becomes bigger and bigger.