Abstract
Nickel-based superalloys are widely employed in aerospace and other fields on account of excellent performance. However, the tool is easily worn out in cutting of superalloys, which will deteriorate the surface quality and lower the service life of the components. In this paper, the effect of ceramic tool wear on surface integrity during high-speed turning of superalloy GH4169 was studied. The results demonstrate that tool wear raises cutting temperature and cutting force. The wear mechanisms of the rake face of the ceramic tool are adhesive wear and oxidation wear, and the wear mechanisms of the flank face are adhesive wear, oxidation wear and abrasive wear. The enhancement effect of tool wear on thermal effect is greater than that on mechanical effect, which forms a larger tensile residual stress on the machined surface. In addition, tool wear increases the thickness of the plastic deformation layer, raising the KAM value from 0.43° to 0.63° at a cutting speed of 200 m/min.
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