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<p>In order to solve the problem of difficult machinability of nickel-based superalloy GH4169 and the complex failure problem of ceramic tools in high-speed cutting, this paper innovatively combines finite element simulation and dry turning experiments to systematically study the wear mechanism of Ceron ceramic tools under extreme thermal–mechanical coupling. Through orthogonal experimental design, the sensitivity of cutting parameters to tool failure was quantitatively analyzed: when the cutting speed was increased from 100 to 240&#xa0;m/min, the temperature of the cutter–chip contact zone increased by 42%, resulting in a 2.1-fold increase in the growth rate of flank wear (VB). When the feed rate increases from 0.05 to 0.2&#xa0;mm/r, the VB value in the initial wear stage increases exponentially. When it exceeds 0.3&#xa0;mm, the wear mechanism changes from bond wear (65%) to diffusion–oxidation coupling failure (82%). The study revealed that at a parameter window of <i>v</i> = 200&#xa0;m/min, <i>f</i> = 0.15&#xa0;mm/r, the wear life of the Sailon tool could be increased by 37% by optimizing the hydrodynamic pressure effect during chip formation. The quantification model of tool failure under the combination of thermo–chemical–mechanical interaction proposed in this paper provides theoretical support for the optimization of high-efficiency machining parameters of superalloys.</p>

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Simulation of machining parameters and tool wear mechanism of high-speed turning of superalloy GH4169 with ceramic tool

  • 期刊论文

  • 发表日期：

    2025年5月14日

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  • Yuansheng Zhai,
  • Guorui Zhang,
  • He Zhang

摘要

In order to solve the problem of difficult machinability of nickel-based superalloy GH4169 and the complex failure problem of ceramic tools in high-speed cutting, this paper innovatively combines finite element simulation and dry turning experiments to systematically study the wear mechanism of Ceron ceramic tools under extreme thermal–mechanical coupling. Through orthogonal experimental design, the sensitivity of cutting parameters to tool failure was quantitatively analyzed: when the cutting speed was increased from 100 to 240 m/min, the temperature of the cutter–chip contact zone increased by 42%, resulting in a 2.1-fold increase in the growth rate of flank wear (VB). When the feed rate increases from 0.05 to 0.2 mm/r, the VB value in the initial wear stage increases exponentially. When it exceeds 0.3 mm, the wear mechanism changes from bond wear (65%) to diffusion–oxidation coupling failure (82%). The study revealed that at a parameter window of v = 200 m/min, f = 0.15 mm/r, the wear life of the Sailon tool could be increased by 37% by optimizing the hydrodynamic pressure effect during chip formation. The quantification model of tool failure under the combination of thermo–chemical–mechanical interaction proposed in this paper provides theoretical support for the optimization of high-efficiency machining parameters of superalloys.