Abstract
Improving the cutting efficiency is the major factor for improving the processing of nickel-based alloys. The novelty of this research is the calibrated SiAlON ceramic tool dry milling nickel-based alloy process. Firstly, the nickel-based alloy dry milling process was analyzed through the finite element method, and the required milling force and temperature were deduced. Then, several dry milling experiments were conducted with the milling temperature, and the milling force was monitored. The change in cutting speeds was from 400 m/min to 700 m/min. Experimental results verified the reduction of the dry milling force hypothesized by the simulation. The experiment also indicated that with a cut depth of 0.3 mm, cut width of 6 mm, and feed per tooth of 0.03 mm/z, when milling speed exceeded 527.52 m/min, the milling force began to decrease, and the milling temperature exceeded the nickel-based alloy softening temperature. This indicated that easy cutting could be realized under high-speed dry milling conditions. The interpolation curve about average temperature and average milling forces showed similarity to the tensile strength reduction with the rise of temperature.
Highlights
A nickel-based superalloy refers to an alloy with high strength and good resistance to oxidation at high temperatures together with good creep behavior, as Suárez et al [1] and Polvorosa et al [2] stated.Yu et al [3] and Marques et al [4] reported that these alloys have been widely used in gas turbines, aero engines, and other key components in the aeronautics industry, and the machining productivity improvement has attracted great research attention [5]
14,500 mm3 /min, under a cutting speed of 720 m/min, which could lead to a high material removal rate of the nickel-based alloy, further increasing the milling efficiency of this hard-to-cut material
As the cutting speed was in direct proportion to cutting temperature at the shear zone, the change of cutting speed could lead to a change of milling temperature in the shear zone
Summary
A nickel-based superalloy refers to an alloy with high strength and good resistance to oxidation at high temperatures together with good creep behavior, as Suárez et al [1] and Polvorosa et al [2] stated. López de Lacalle L.N. et al [20] put forward the plasma-assisted milling for three low machinability alloys, and nickel-based alloys could be processed under high cutting speeds with the improvement of tool life. 14,500 mm3 /min, under a cutting speed of 720 m/min, which could lead to a high material removal rate of the nickel-based alloy, further increasing the milling efficiency of this hard-to-cut material. High speed and high-efficiency machining method for nickel-based alloy was proposed to solve the problem of low material removal rate caused by cutting force and excessive cutting heat during the dry milling process. The high-speed dry milling process of nickel-based alloy showed a thermal softening effect for the workpiece material. By using the thermal softening effect, a high material removal rate of the nickel-based alloy was achieved, which could increase the milling efficiency of nickel-based alloy
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