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<p>Deep-hole pull boring is essential for machining high length-to-diameter ratio (L/D &gt; 40) components, especially in aerospace and other high-performance industries. Due to its poor machinability, nickel-based superalloy GH4169 in deep-hole pull boring poses significant challenges, including severe tool wear, high cutting temperatures, and difficulties in chip evacuation. This study investigates tool wear mechanisms and cutting performance in deep-hole pull boring of GH4169, focusing on optimizing tool structure and process parameters. By incorporating a force analysis model, the proposed BTA deep-hole pull boring with three guide pads achieves a 50% reduction in tool and guide pad wear while maintaining surface roughness at 1.6–1.8&#xa0;µm during stable boring under the parameters of <i>n</i><sub><i>t</i></sub> = 165 r/min, <i>n</i><sub><i>w</i></sub> = 70 r/min, and <i>v</i><sub><i>f</i></sub> = 16&#xa0;mm/min. Rake and flank wear are dominated by adhesive and abrasive wear, with built-up edges on the main cutting edge, boundary groove wear on the minor flank face and vibration wrinkles on the flank face. Guide pads wear at the inlet end involves adhesive wear, abrasive wear, coating delamination, and chemical, oxidation, and diffusion wear. Chips are primarily C-shaped and short spirals, validating efficient chip evacuation design.</p>

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Investigation of tool wear mechanism and cutting performance in deep-hole pull boring of GH4169

  • 期刊论文

  • 发表日期：

    2025年8月29日

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  • Guo Lin,
  • Liang Zhiqiang,
  • Du Yuchao,
  • Zhang Rui,
  • Gao Mingchang,
  • Hu Junhua,
  • Yi Linfeng,
  • Chang Guozheng

摘要

Deep-hole pull boring is essential for machining high length-to-diameter ratio (L/D > 40) components, especially in aerospace and other high-performance industries. Due to its poor machinability, nickel-based superalloy GH4169 in deep-hole pull boring poses significant challenges, including severe tool wear, high cutting temperatures, and difficulties in chip evacuation. This study investigates tool wear mechanisms and cutting performance in deep-hole pull boring of GH4169, focusing on optimizing tool structure and process parameters. By incorporating a force analysis model, the proposed BTA deep-hole pull boring with three guide pads achieves a 50% reduction in tool and guide pad wear while maintaining surface roughness at 1.6–1.8 µm during stable boring under the parameters of nt = 165 r/min, nw = 70 r/min, and vf = 16 mm/min. Rake and flank wear are dominated by adhesive and abrasive wear, with built-up edges on the main cutting edge, boundary groove wear on the minor flank face and vibration wrinkles on the flank face. Guide pads wear at the inlet end involves adhesive wear, abrasive wear, coating delamination, and chemical, oxidation, and diffusion wear. Chips are primarily C-shaped and short spirals, validating efficient chip evacuation design.