Tool Wear And Life Prediction Of Micro-textured Tools Cutting Nickel-based Superalloy In Spray Cooling

GH4169 is a nickel-based superalloy with high hardness,high strength,high temperature resistance and corrosion resistance.Composed of many elements Nibased superalloy has high creep resistance and excellent thermal stability.Because of these unique physical properties of Ni-based superalloy,severe tool wear and short tool life happen to common tools in cutting.Combined with bionics,this paper put forward the design of micro-textured cutting tools.Micro-textures of different shapes were machined on the rake face of cemented carbide cutting tools.When GH4169 was cut in spray-cooling,experiment and simulation were both conducted and the results were put into comparison and analysis.In order to achieve the minimum wear of cutting tools,the tool wear and tool life of micro-textured tools were analyzed and predicted.The main points of research are listed as follows:（1）Tool wear on the rake face was analyzed,and the effective working area and arrangement of micro-textures was optimized.Based on bionics,five different types of micro-textures were designed and applied to the rake face of cemented carbide inserts.（2）The DEFORM-3D cutting simulation model in spray cooling was established,and the tool wear simulation analysis was carried out.The tool wear on rake face of different morphological micro-textures was analyzed,and the the morphology of micro-texture with the smallest change of wear depth was selected.（3）After the target morphology of micro-texture was selected,several dimension parameters of the texture were given for dimension simulation.In the same working conditions,one set of optimal dimension parameters was obtained in simulation for the goal of achieving the minimum wear depth on rake face of tools.Then the microtextured tool of these optimal dimension parameters was employed in cutting simulation with different cutting parameters.Analysis is carried out about the cutting simulation and a set of optimal cutting parameters was obtained for the goal of achieving the minimum tool wear depth on rake face and the lowest cutting temperature as well.（4）To analyze the tool wear on rake face of the micro-textured tools,this research conducted cutting test in spray cooling.With the use of micro-element method,the wear areas on rake faces of the five micro-textured morphologies were estimated firstly,and then the wear areas of tool rake faces with different micro-texture dimension parameters were estimated in terms of the pits in micro-textures.By analyzing the influence and action rule of the distance between micro-texture of pits and cutting edge,pit diameter and pit spacing on tool wear,one set of micro-texture dimension parameters were optimized and compared with the corresponding simulation results.（5）In step turning test,tool life was predicted for both non-textured tools and the micro-textured tools with optimal parameters.The influence of micro-textures on tool life was analyzed in terms of adhesion,diffusion and abrasive wear.