Performance of PCBN tools in high-speed milling nickel-based superalloy

Abstract

The cutting forces, tool wear and wear mechanism were investigated based on the high-speed dry milling of nickel-based superalloy GH4169 using polycrystalline cubic boron nitride (PCBN) tools. The effects of cutting speed and axial depth of cut on the cutting forces were obtained, and the effects of cutting speed, feed per tooth and axial depth of cut on PCBN tool wear were discussed. It was noted that tool wear was minimal at the maximum cutting speed 1065 m min−1 and the maximum feed rate 0·12 mm tooth−1 in this study. The scanning electron microscope and energy-dispersive X-ray spectroscopic analysis showed that the main failure modes of PCBN tools were rake crater wear, flaking, chipping, flank wear and notch wear. Besides, the dominant wear mechanisms were flaking and chipping caused by mechanical impact, adhesion wear, diffusion wear and chemical wear.