Abstract
In recent years, most of nickel-based materials have been used in aircraft engines. Nickel-based materials applied in the aerospace industry are used in a wide range of applications because of their strength and rigidity at high temperature. However, the high temperatures and high strength caused by the nickel-based materials during cutting also reduce the tool lifetime. This research aims to investigate the tool wear and the surface roughness of Waspaloy during cutting with various cutting speeds, feed per tooth, cutting depth, and other cutting parameters. Then, it derives the formula for the tool lifetime based on the experimental results and explores the impacts of these cutting parameters on the cutting of Waspaloy. Since the impacts of cutting speed on the cutting of Waspaloy are most significant in accordance with the experimental results, the high-speed cutting is not recommended. In addition, the actual surface roughness of Waspaloy is worse than the theoretical surface roughness in case of more tool wear. Finally, a set of mathematical models can be established based on these results, in order to predict the surface roughness of Waspaloy cut with a worn tool. The errors between the predictive values and the actual values are 5.122%∼8.646%. If the surface roughness is within the tolerance, the model can be used to predict the residual tool lifetime before the tool is damaged completely. The errors between the predictive values and the actual values are 8.014%∼20.479%.
Highlights
The development of engine design aims at the applications under high pressure and high temperature, in order to improve the fuel efficiency and to save the related costs
They have been widely used in aerospace industry, petrochemical industry and other fields
Hanasaki et al [4] discovered that the coated tool supports better resistance on the groove wear and the tool wear when cutting a nickel-based alloy with a tungsten carbide tool with a specific coating. ey pointed out that the tool lifetime depends on the tool chipping and the adhesion wear during the low-speed cutting and depends on the wear caused by the tool temperature increases during the high-speed cutting
Summary
The development of engine design aims at the applications under high pressure and high temperature, in order to improve the fuel efficiency and to save the related costs. Ey support, especially, better high-temperature resistance than low-alloy steel and stainless steel in case the temperature is higher than 650°C. In recent years, they have been widely used in aerospace industry, petrochemical industry and other fields. Hanasaki et al [4] discovered that the coated tool supports better resistance on the groove wear and the tool wear when cutting a nickel-based alloy with a tungsten carbide tool with a specific coating. Ey pointed out that the tool lifetime depends on the tool chipping and the adhesion wear during the low-speed cutting and depends on the wear caused by the tool temperature increases during the high-speed cutting. E thesis on machining mostly issue on tool wear and optimization parameter, this study mainly objects at the simultaneous prediction of tool wear and surface roughness to for the nickel-based alloy Waspaloy
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