Abstract
Nickel-based alloys are widely applied in the industry. It is important to think highly of production quality and speed. Nickel-based alloys have high strength, high heat resistance, and corrosion resistance. During the cutting process, these characteristics will bring a lot of processing problems such as surface roughness, machining efficiency, and tool wear. Therefore, through the composite concept, computer numerical controlled lathe with plasma welding machines to improve processing problems was combined. Plasma-assisted machining involves plasma heat source heating to the surface of the partial material before the cutting process. Partial material will increase the temperature to achieve heat-softening effect. This approach could reduce the hardness of material and help to conduct the cutting process with tools. The conventional machining was compared with plasma-assisted machining by experiment. Their different cutting speed, feed rate, cutting depth, and the current size were investigated. The result shows that plasma-assisted machining could reduce the cutting forces efficiently.
Highlights
Today, nickel-based superalloy has been applied to aerospace industry and national defense industry widely because of the excellent mechanical properties, fatigue resistivity, and corrosion resistivity under conditions of high temperature
The results showed that the cutting force can be reduced 25%, the lifetime of cutter can be extended about 100%, and the removal rate can be enhanced about 250%
The results showed that the cutting force can be reduced 25%, surface roughness can be improved 2–3 times, and the lifetime of cutter can be extended 200%–300% if the removal temperature of materials is increased from the room temperature to 360°C
Summary
Nickel-based superalloy has been applied to aerospace industry and national defense industry widely because of the excellent mechanical properties, fatigue resistivity, and corrosion resistivity under conditions of high temperature. Applying the heat source of plasma-assisted machining (PAM) to soften materials first will create an extremely short heating duration before the cutter reaches workpieces. The results showed that the cutting force can be reduced 25%, the lifetime of cutter can be extended about 100%, and the removal rate can be enhanced about 250%. It indicated that the preheating by an additional heat source leads significant influence for machining. The results showed that the cutting force can be reduced 25%, surface roughness can be improved 2–3 times, and the lifetime of cutter can be extended 200%–300% if the removal temperature of materials is increased from the room temperature to 360°C. The strengthening mechanism for nickel-based superalloy can be divided into austenitic-based solid solution strengthening, precipitation strengthening for g# and g$, and grain boundary strengthening.[8]
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