Effect of MQL condition on cutting performance of high-speed machining of GH4099 with ceramic end mills

Abstract

Ceramic tool materials become an ideal choice for machining superalloy materials because of the excellent tolerance to effect of heat, strong chemical stability and high temperature hardness. The present paper focuses on the effects of different cutting environments which are the dry, MQL (pure-oil) and MQL mixed with water on the milling force in each direction, the variation of flank wear, as well as surface topography of workpiece, simultaneously analyzing in deep to the wear mechanism of the mills during distinct technological environments. The results reveal that the milling force of MQL and MQL mixed with water conditions were decreased by 12.8% and 28.2% respectively compared with the dry milling. In terms of the cutting temperature, it was also significantly reduced up to 9.2% and 17.5% separately. In addition, MQL and MQL mixed with water had been successful in improving the surface quality of the workpiece and limiting the tool wear values. Similar to the tool wear mechanism of dry milling, the wear mechanisms of ceramic end mills under MQL and MQL mixed with water were deemed adhesive wear, diffusion wear and notch wear.