Abstract
GH4169 superalloy is widely used in the aerospace industry due to its high specific strength, excellent high-temperature oxidation resistance, good fatigue resistance, and superior creep strength. However, its high strength and low thermal conductivity result in severe tool wear and chip-breaking difficulties during the turning process. This leads to degradation in surface quality and a significant decrease in fatigue resistance. High-pressure cooling lubrication-assisted machining technology can enhance the machinability of this superalloy. In this work, finite element simulation is used to analyze the influence of various high-pressure cooling parameters (injection diameter, angle, and pressure) on chip formation, burr morphology, and tool wear during turning with a polycrystalline cubic boron nitride (PCBN) tool. Comparative experiments are conducted to investigate tool wear, chip morphology, and burr formation under dry and high-pressure cooling conditions, verifying simulation accuracy. The results indicate that dry turning produces long spiral chips and significant tool wear. In contrast, high-pressure cooling changes chip morphology from long to short spirals, reduces burr formation, and decreases tool wear. Optimal parameters include an injection pressure of 50 bar, an angle of 0°, and a diameter of 1.6 mm, which lead to extended tool life, well-formed chips, and reduced burrs.
Published Version
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