Abstract
By analyzing microstructure of the material, a finite element model of high-speed cutting process more close to the practical instance was put forward. The microstructure of nickel-based alloy was obtained based SEM experiment, and the digital model of microstructure was built. Based on above study, finite element model of high-speed cutting of nickel-based alloy integrating macro and micro physical characters was established. Further, finite element simulation and analysis of high-speed cutting of nickel-based alloy were conducted, and the saw-tooth chip, cutting force variation curve and cutting temperature field distribution pictures were got. Research shows that grain boundary occur serious distortion at chip and tool contact area during saw-tooth chip forming, and the grain boundary structure changes will cause the change of cutting force during generating adiabatic shear band. So reducing cutting force and improving the processing quality can be achieved by changing the internal microscopic structure of workpiece.
Highlights
Nickel-based alloy material is a kind of widely applied in the aviation materials [1]
Christian et al simulated the serrated chip formation process of Inconel 718 using ABAQUS/Explicit grid adaptive function [6]; Lv Shaoyu investigated cutting process of nickel-based superalloy GH4169 using AdvantEdge finite element analysis software, and the machined surface temperature, strain and strain rate distribution were got, whose research showed that higher temperature and higher strain, strain rate appeared surface contact area for nickel-based alloy GH4169 [7]; Zhou Jun studied the changing rule of the adiabatic shear band inside the serrated chip through the experimental during high-speed cutting nickel-based alloy GH4169 [8]
It can be seen from the diagram that the grain boundary structure in the adiabatic shear zone happened serious distortion
Summary
Nickel-based alloy material is a kind of widely applied in the aviation materials [1]. Due to coefficient of thermal conductivity of nickel-based alloy material is small, high temperature, high chemical activity in the process of cutting tend to forms alloy with knives, making a kind of typical difficult-to-machine materials [2,3]. With the continuous improvement of computer performance, finite element simulation technology becomes a new mean to high speed cutting process of the refractory materials [4,5]. Christian et al simulated the serrated chip formation process of Inconel 718 using ABAQUS/Explicit grid adaptive function [6]; Lv Shaoyu investigated cutting process of nickel-based superalloy GH4169 using AdvantEdge finite element analysis software, and the machined surface temperature, strain and strain rate distribution were got, whose research showed that higher temperature and higher strain, strain rate appeared surface contact area for nickel-based alloy GH4169 [7]; Zhou Jun studied the changing rule of the adiabatic shear band inside the serrated chip through the experimental during high-speed cutting nickel-based alloy GH4169 [8]
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