Initial Wear Stage Research Articles

The generation mechanism of cutting heat and the theoretical prediction model for temperature on the rake face of the cutting tool in Zirconia ceramics

Cutting temperature and its distribution are crucial factors influencing tool strength and wear rate, due to the hardness and brittleness of Zirconia (ZrO2) ceramics, significant challenges arise in both direct temperature measurement in the cutting zone and theoretical analysis of cutting heat. Thus, focusing on the turning characteristics of ZrO2 ceramics, this study analyzes the mechanism of cutting heat generation and proposes utilizing thermodynamic state equations to determine the cutting heat source on rake face of tool. Based on the heat source method, a theoretically prediction model for temperature distribution on rake face is established. This model considers primary cutting parameters, workpiece material properties, crack fracture characteristics of the machined surface, and thermal characterizations of the tool material. The relationship between tool wear and cutting temperature is experimentally analyzed to determine the characteristic temperature that indicates the initial stage of tool wear. The validity of the theoretical model is verified, as the predicted results show high consistency with experimental results within the range of experimental parameters, with a relative error within 15.2 %.The results reveal the highest temperature during brittle cutting occurs within the cutting layer area, with the highest temperature occurring approximately 50 μm from the tool tip, followed by a gradual decrease beyond 150-200 μm. This study also demonstrates that cutting heat in ceramic turning does not solely originate from friction heat between tool flank-workpiece but also includes impact heat from tool rake face-workpiece, which under certain cutting parameters exerts a more significant influence on cutting temperature. This model can facilitate the selection and optimization of cutting process parameters for brittle materials and provide a theoretical basis for analyzing the relationship between tool thermal damage, thermophysical properties, and tool wear.

A dual-stage wear rate model based on wear mechanisms analysis during cutting Inconel 718 with TiAlN coated tools

Inconel 718 is recognized as the difficult-to-cut material. TiAlN coated tool is frequently applied in machining of such material, due to its excellent hot hardness and oxidation resistance. However, research on the wear rate model during the cutting of Inconel 718 with TiAlN coated tools is limited. Therefore, this paper proposes a novel dual-stage wear rate model to predict wear of TiAlN coated tools when cutting Inconel 718 using finite element (FE) simulation. The dual-stage model integrates impacts from adhesive wear, diffusion wear and abrasive wear, and includes two wear rate models for the initial wear stage and steady wear stage, respectively. Subsequently, an in-depth analysis of tool wear mechanisms is conducted through Energy Dispersive Spectrometer (EDS) and Scanning Electron Microscope (SEM) techniques. The analysis results reveal that the adhesive wear dominates in the initial wear stage, while the steady wear stage witnesses the concurrent involvement of abrasive wear, diffusion wear and adhesive wear. Moreover, extensive cutting experiments validate that the model can predict wear of the TiAlN coated tools with an error margin of less than 8.5 %.

Wear behaviour of abrasive tools and its effect on surface integrity during polishing superalloy GH4169G with abrasive cloth flap wheels

In polishing nickel-based superalloys, the surface quality and dimensional accuracy of the workpiece are closely related to the wear of the abrasive tools. Over the years, several researchers have studied the wear of grinding wheels or abrasive belts, including the effects of various machining methods, abrasive materials, and machining parameters on the wear of abrasive tools. However, there is not enough research on the wear mechanism of the abrasive cloth flap wheel (ACFW). In this paper, during polishing GH4169G with ACFW, the wear evolution mechanism of ACFW and its effect on the surface integrity of GH4169G were investigated. First, the variations in material removal and ACFW wear amounts during the polishing process were analysed, and the different wear stages were divided based on the polishing ratio. Second, the mic-morphology and surface element distribution of ACFW at different wear stages were investigated using SEM and, EDS, and the wear evolution mechanism of ACFW was analysed. Finally, the effects of ACFW wear on the surface morphology, surface oxidation and microstructure of GH4169G were investigated by SEM, EDS, XRD, and EBSD. The results showed that the primary wear forms of ACFW were stepped fracture, cleavage fracture, blunt, pull-out, and adhesion wear. During the initial wear stage, the proportion of each wear form was relatively balanced. In the medium wear stage, fracture wear was the main wear form. Blunt and adhesive wear were the primary forms of wear during the final wear stage. In addition, with ACFW wear, the surface roughness tend to decrease first and then increase, however, the refinement level of the grains, the intensity of plastic deformation and the intensity of the oxidation reaction gradually increased. This study provides effective guidance for developing more wear-resistant abrasive tools and optimising the grinding and polishing processes.

Enhancing Wear Resistance in Functionally Graded Metallic Components: Insights from Nanoindentation and Mechanical Analysis.

To manufacture metallic components with high wear resistance, treatments such as nitriding and carburising followed by quenching and tempering (NQT and CQT, respectively) are applied to various types of steel to increase the hardness (H) of the friction surface. However, the wear mechanism of the resulting functionally graded materials has not been fully understood. In this study, specimens of industrial 99.82% pure iron treated with NQT at 913 and 1033 K, and CQT at 1203 K, as well as hot-rolled sheets without heat treatment were examined by performing nanoindentation tests to measure changes in their H, reduced Young's moduli (Er), elastic deformation energies (We), and plastic deformation energies (Wp) along the depth direction. The relationship between Wp/We and the elastic strain resistance (H/Er) can be expressed for all specimens via the equation Wp/We = -1.0 + 0.16 (H/Er)-1. Furthermore, the obtained H/Er av measured at 5 µm intervals based on the specimen profile and wear volume has a good correlation depending to the sliding distance, as confirmed by the results of the ring-on-plate sliding tests conducted for the carbon-treated, nitrogen-treated, and hot-rolled specimens. This study provides a new approach, using H/Er parameters to identify the dominant factors affecting wear resistance at the initial stage of wear that may contribute to the development of wear-resistant materials.

Research on tool wear state identification method driven by multi-source information fusion and multi-dimension attention mechanism

Cutting tool wear condition monitoring technology is the key technology of advanced manufacturing system and a crucial component of machining. The stage of the tool wear has a direct impact on performance of the workpiece and efficacy of machine tool. However, the duplication and lack of wear information and the fuzzy area of the tool wear transition stage are the key factors contributing to the incorrect estimation of the tool wear state when extracting cutting tool wear feature information. As a consequence, this study presents a data fusion from several sources-based intelligent tool wear state detection technique. The fusion of data from several sources can effectively realize the complementarity of machining information. This provides the model with more comprehensive identification data. The mapping between wear state and wear characteristics is precisely established. To address these issues, the attention mechanism of channel and spatial latitude is integrated into the feature extraction. The model that was constructed in the present investigation has a comprehensive identification accuracy of 0.982. The F1 score of initial, normal and severe wear stage of tool wear are 0.977, 0.968 and 0.993, which are better than other models. Experiments show that the identification method proposed in this study may provide accurate tool wear condition identification based on machining process data, allowing for more flexible and precise cutting tool change decisions in machining.

Running-in behavior of dual-mobility cup during the gait cycle: A finite element analysis.

The running-in process is considered an essential aspect of the comprehensive wear process. The phenomenon of running-in occurs during the initial stages of wear in the prosthetic hip joint. Within the field of tribology, the running-in phenomenon of the hip joint pertains to the mechanism by which the contact surfaces of the artificial hip joint components are adjusted and a suitable lubricating film is formed. During the process of hip joint running-in, there is an interaction between the metal surface of the ball and the joint cup, which results in adjustments being made until a steady state is achieved. The achievement of desirable wear existence and reliable performance of artificial hip joint components are reliant upon the tribological running-in of the hip joint. Despite the establishment of current modeling approaches, there remains a significant lack of understanding concerning running-in wear, particularly the metal-on-polyethylene (MoP) articulations in dual-mobility cups (DMC). An essential aspect to consider is the running-in phase of the dual mobility component. The present study employed finite element analysis to investigate the running-in behavior of dual mobility cups, wherein femoral head components were matched with polyethylene liners of varying thicknesses. The analysis of the running-in phase was conducted during the normal gait cycle. The results of this investigation may be utilized to design a dual-mobility prosthetic hip joint that exhibits minimal running-in wear.

Surface wear resistance and microstructure characteristic in longitudinal–torsional ultrasonic vibration side milling of GH4169 superalloy

The intrinsic link between the surface wear resistance and microstructural evolution of a material was revealed. The surface wear resistance of the GH4169 superalloy was systematically investigated in relation to the surface machining topography and mechanical properties at different cutting widths in conventional side milling (CSM) and longitudinal–torsional ultrasonic vibration side milling (LTUVSM). The wear resistance was evaluated by analyzing the wear topography, friction coefficient, duration of the initial wear stage (IWS), and wear volume of dry sliding wear. The specimens in LTUVSM exhibited higher wear resistance than those in CSM owing to the inhibition of friction and growth of inter-surface friction nodes by the uniform ultrasonic vibration texture (UVT) and the inhibition of subsurface crack nucleation and extension by the superior mechanical properties. The mechanism of the ultrasonic vibration intervention in grain refinement was revealed. The involvement of ultrasonic vibration enhanced the dislocation accumulation, the grain boundary fractures, and increased the recrystallization fraction, which resulted in a thorough grain refinement with a 7.3 % decrease in average grain diameter (AGD) relative to that obtained with CSM. The increased grain refinement in LTUVSM improved the mechanical properties of the surface-layer material, thereby improving the wear resistance of the specimen.

Cutting performance and wear characteristics of Si3N4–SiCw–HfB2 ceramic cutting tools in turning of ductile cast iron

AbstractThis research investigated the cutting performance of three different types of Si3N4‐based ceramic tools (Si3N4, Si3N4–SiCw, and Si3N4–SiCw–HfB2) with distinct mechanical properties during turning of ductile cast iron. Si3N4 ceramic tool, characterized by high hardness and low toughness, showed minor micro‐chipping and the highest average flank wear rate during the initial wear stage, leading to a short cutting life of 1679 m. Si3N4–SiCw ceramic tool, with low hardness and high toughness, exhibited the highest average flank wear rate during the middle and final wear stages, resulting a short cutting life (1602 m). In contrast, the Si3N4–SiCw–HfB2 ceramic tool, featuring high hardness and high toughness, demonstrated the lower average flank wear rate during all the wear stages, leading to a longest cutting life (2636 m). The results indicated that the average flank wear rate during the initial wear stage was mainly influenced by toughness, while during the middle and final wear stages, the average flank wear rate was primarily dependent on hardness.

A comprehensive research on wear resistance of GH4169 superalloy in longitudinal-torsional ultrasonic vibration side milling with tool wear and surface quality

To improve the service and machining performance of the workpiece, the tool wear mechanisms, surface machining quality, and wear resistance in conventional side milling (CSM) and longitudinal-torsional ultrasonic vibration side milling (LTUVSM) of GH4169 superalloy at different cutting lengths are investigated systematically. Tool wear mechanisms are revealed and the correlation between machined surface quality with tool wear is analyzed correspondingly. Tool wear patterns mainly include adhesive wear, diffusion wear, abrasive wear, and chipping sticking. Better surface quality is achieved in LTUVSM due to a maximum reduction of flank wear bandwidth and wear rate by 71.9% and 71.5%, respectively, compared to CSM. The friction coefficient, initial wear stage time, and wear volume of dry sliding wear were measured to evaluate the workpiece wear resistance. The maximum reductions in friction coefficient and wear volume in LTUVSM are 18.2% and 15.8% compared to CSM. The regular ultrasonic vibration textures suppress the friction and the growth of contact nodes in the contact area, decreasing the degree of surface wear, which is demonstrated by a 38.8% increase in initial wear stage time compared to CSM. In conclusion, the workpiece in LTUVSM exhibits higher wear resistance because of the improvement of tool wear and the guarantee of surface quality.

Researches on tool wear progress in mill-grinding based on the cutting force and acceleration signal

Tool wear progression has greatly impact on the machining quality, tool wear evaluation is useful to obtain tool states. Mill-grinding experiments are performed using the electroplated diamond tool to reveal tool wear progression. Both time and frequency domain, dimensional and dimensionless characteristics of cutting force and acceleration signals are analysed. Among time domain characteristics, peak and average values exhibit low and stable amplitudes at the initial wear stage, and evolve to large and fluctuant amplitudes at the severe wear stage. For frequency domain analysis, gravity frequency exhibits a decrease trend with tool wear progression. Among dimensionless characteristics, kurtosis and margin factors show a maximum value when tool wear progression goes into the severe wear stage, and can be applied to evaluate tool wear progression. Tool wear modes include the wearing flat process and fracture of diamond grains, tool wear mechanisms include the abrasive wear, adhesive wear and grain fracture.

Mixed thermo-elasto-hydrodynamic lubrication and wear coupling simulation analysis for dynamical load journal bearings

In the crankshaft-connecting rod system of the diesel engine, the complicated lubrication and wear mechanisms of journal bearings are comprehensively affected by the elastic deformation effect, the asperity contact effect, the thermal effect as well as the lubricating oil viscosity-temperature effect. This paper proposes an adaptive iterative method based on a mixed thermo-elasto-hydrodynamic (TEHD) lubrication and wear coupling model to investigate the lubrication and wear behaviors of journal bearings in the mixed lubrication. The evolution laws of the oil film thickness, the hydrodynamic pressure, the asperity contact pressure, the friction power loss, and the wear distribution are discussed and compared under different running times, oil temperatures, external loads, and shaft rotational speeds. The three-dimensional surface models based on the asperity contact power loss and the maximum wear depth with the variation of the running time and the oil temperature are fitted under specific external loads and shaft rotational speeds. The simulation results demonstrate that the bearing wear process includes the initial wear stage and the stable wear stage, which has a significant influence on the changing trend and distribution of lubricating parameters. The three-dimensional surface fitting models can provide theoretical guidance for the future performance prediction of journal bearings under time-varying working conditions.

A new model to predict the tool life in turning of titanium aluminides

Several tool wear models for machining operations have been reported in the literature. However, most of them are capable of modeling only a part of the wear curve, designed for quasi-linear curves or need to be fitted by means of differential equations. In this research, a new analytical easy-to-use wear model is proposed, taking into consideration the geometry of the cutting insert and the influence of the cutting speed and the tool-workpiece contact stress. In addition, the effect of the critical machining time, relative to the tool degradation, has also been introduced. The wear model describes completely the wear curve, from the initial rapid wear stage to the thermal-activated wear rate acceleration. The constants and parameters of the equation are determined by cutting experiments from the cutting forces and flank wear registers under a variety of technological parameters. This model has been validated for turning process on Ti48Al2Cr2Nb aluminide with uncoated carbide tool under different cutting conditions, varying the cutting speed and the geometrical position of the tool. It has been demonstrated its suitability to predict tool life, according to a defined wear criterion.

Study on milling tool wear morphology and mechanism during machining superalloy GH4169 with PVD-TiAlN coated carbide tool

Tool life, dimension accuracy and surface quality of workpiece, intelligent operation and maintenance of automated production are closely related to tool wear. However, for many years, relevant scholars have mainly focused on the research of the tool wear mechanism in the sharp wear stage, mainly involving various machining methods, various superalloy materials, various tool materials and geometric parameters, and different coolant methods et, al. The morphology and mechanism of tool wear need to be further studied in the initial and steady wear stage, which is helpful to ensure the dimensional accuracy and surface quality of workpiece, especially in the finishing stage. 45 groups of tool wear experiments are carried out under dry condition during milling of GH4169 with PVD-TiAlN coated carbide tools. The tool wear micro-topography, tool wear curve, tool cutting force, spindle motor current, tool wear mechanism, chip topography and machined surface topography were investigated during the milling tool wear. The tool wear mechanism in the sharp wear stage was further explored by SEM, EDS and XRD, which will help to deeply gain the milling characteristics of GH4169 and help to test the cutting performance of the tool. The results show that during the tool wear process of milling superalloy GH4169, severe abrasive wear and adhesive wear occur in large numbers, the rate of tool wear is fast, the cutting force increases, the current of the spindle motor increases, and the tool coating and substrate material were worn seriously, the main tool wear mechanisms are abrasive wear, adhesive wear, oxidative wear and breakage. Severe abrasive wear occurs between lots of hard abrasive carbides in the workpiece material and the rake and flank faces of the milling tool. Fe, Cr, Al, etc. were found on the rake and flank faces, and the adhesive wear was very serious. Many oxides (Al2O3, Fe2O3, etc.) appear on the rake and flank surfaces, which indicate that oxidative wear occurs. Due to the periodic intermittent cutting during the milling process, the breakage of milling tool edge is very serious. Chips or adherents with different microscopic topographies were adhered to the tool wear area due to extrusion and stretching in the sharp wear stage. The machined surface micro-topography of the workpiece, which affected by tool wear, was greatly of difference during the entire wear stage.

A novel microwall sliding test uncovering the origin of grain refined tribolayers

The tribology induced microstructure determines the tribological properties of metals. Yet the complex interaction of multiple microcontacts makes it impossible to decouple the fundamental plastic mechanisms. Single nano-/microasperity sliding tests allow to separate the microcontacts and to study the origins of plastic evolution during the initial stages of wear. However, the fundamental formation mechanisms of the sliding induced grain refinement are still largely unknown. In this work, we pre-remove material around the wear track and produce microwalls, which simplify the stress state and allow to directly inspect the contact zone. After sliding on the microwalls, a misorientation jump forms in the crystal orientation below the wear track. The crystallographic misorientation reaches 30° in some configurations, resulting in the formation of large angle grain boundaries. The misorientation jump formation depends on the grain orientation, wear direction and on twin boundaries in its path. We unravel the grain formation mechanism via slip-step and dislocation analysis and address dislocation arrangements at the grain boundary. This novel microwall sliding test has a potential to better understand the origins of microstructure modification in metals during the run-in stage of wear.

Structure and operating algorithms of the system for monitoring of the shaft’s axial dis-placement in combined journal-and-thrust bearing of the turbo-pump unit of liquid-propellant rocket engine NK-33

The problem of early wear diagnostics of the combined journal-and-thrust bearing of the turbo-pump unit of the liquid-propellant rocket engine NK-33 is considered. The main purpose of the diagnostics is to identify the initial stage of the bearings intensive wear. This allows to detect timely the catastrophic destruction of the unit and to prevent the development of emergency destruction of the power plant in general. The significant limitation of the appropriate diagnostic methods was the strict requirements of the inadmissibility of any changes on the number and dimensions of the sensors used in the product body while the existing functions of the turbopump rotor rotation speed monitoring should remain unchanged. The authors proposed a solution based on the replacement of the inductive RPM sensors that are currently used in the turbopump unit parameter monitoring systems with single-coil eddy current sensors with sensitive elements in the form of a conductor segment. This approach made it possible to monitor the axial displacement of the shaft in the combined journal-and-thrust bearing associated with the wear of the assembly and to keep the function of the measuring of the turbopump shaft rotational speed unchanged. The article provides a brief description of the implemented approach to early diagnosis of the condition of the bearing assembly of the NK-33 turbopump unit based on the measurement of the axial displacement of the shaft in the bearing. The technical solutions that implement the approach are based on the use of original single-coil eddy current sensors of a special design with shifted sensing elements, the non-standard converters of their output signals in combination with standard analog-to-digital converters (external modules of the Russian-made L-Card E14-440 ADC) and a PC that provides the control of the data aquisition, processing and visualization. A structural and functional scheme of the control system and its generalized operation algorithm are proposed.

Investigation on WEA fatigue spalling of U71MnG rail material subject to laser quenching surface treatment

In this study, the fatigue spalling process and mechanism of the white etched area (WEA) caused by the laser quenching surface treatment of U71MnG rail material were investigated. The results demonstrate that the surface pearlite is visibly deformed under normal stress and creep force during the initial wear stage, whereas the WEA is not deformed. Discordant plastic deformation results in the formation of cracks at the contact between the initial position of the WEA and the substrate, which then propagates into the WEA. As the number of rolling cycles increases, the formation and propagation of cracks gradually shift into the middle of the WEA and branch cracks form, which eventually intersect and cause spalling. The substrate's plastic flow covers the WEA terminal position surface; the WEA edge fracture is formed due to bending under normal stress. Plastic deformation enhances the surface hardness of WEA. The substrate's apparent plastic deformation beneath the WEA suggests that the WEA flows under the influence of creep forces.

Wear evolution of electroplated diamond abrasive belt and corresponding surface integrity of Inconel 718 during grinding

Serious wear can easily occur in traditional abrasive belts during grinding nickel-based superalloy components. To find an abrasive belt with excellent wear resistance and surface finishing, this study uses electroplated diamond abrasive belt (EDAB) to grind Inconel718, and investigates its wear evolution and corresponding grinding surface integrity. It was revealed that EDAB showed stable grinding performance, and the wear mechanism in initial, steady, and final wear stage was primarily micro cleavage fracture, macro cleavage fracture and adhesive wear, respectively. As EDAB wore, ground surface roughness gradually decreased and reached a minimum of Ra0.5 µm, and subsurface crystalline grains of Inconel718 were refined. Furthermore, the abrasive belt wear was significantly reduced and the surface integrity was improved using low-hardness contact wheels.

A dynamic detection method for polygonal wear of railway wheel based on parametric power spectral estimation

Severe wheel polygon will cause the strong repeated wheel-rail excitation, accelerating the failure of vehicle key components. Nevertheless, the traditional spectral estimation methods are not ideal for dealing with these wheel fault signals, making the characteristic frequencies caused by wheel polygon hardly detected. This paper proposes a dynamic detection method for wheel polygon based on parametric power spectral estimation for the first time. Firstly, according to the dynamic characteristics of the wheel polygon, the harmonic frequency recovery model is established. Secondly, the order of the harmonic frequency recovery model is determined based on singular value decomposition and normalised error analysis. Then, the total least square method is used to calculate the parameters of the harmonic recovery model. Finally, the power spectrum of the fault signal is evaluated according to the Cadzow estimation theory. The simulation signal and the measured axle-box vertical vibration acceleration signal of a metro vehicle are taken as case studies to verify the feasibility and effectiveness of the proposed method thoroughly. The results show the proposed method can avoid the inherent defects of traditional detection and analysis methods, weaken the influence of background noise, and is highly advantageous in detecting the initial stage of wheel polygonal wear.

A Dynamic Wear Prediction Model for Studying the Interactions between Surface Wear and Dynamic Response of Spur Gears

Surface wear, as a major failure mode of gear systems, is an unavoidable phenomenon during the whole life of gears. It also induces other gear damages, such as fatigue cracks, surface pitting and spalling. Ultimately, those defects may result in the sudden failure of a gearbox transmission system, which can lead to a serious accident and unexpected economic loss. Therefore, it can provide huge cost and safety benefits to industries to monitor gear wear and predict its propagation. Gear wear raises the error rate of gear transmission systems, typically leading to improvements in dynamic loads, vibration, and noise. In return, the increased load conversely aggravates wear, creating a feedback cycle between dynamic responses and surface wear. For this purpose, a wear prediction model was incorporated into a tribo-dynamic model for quantitatively investigating how surface wear and gear vibration are mutually affected by each other. To obtain more precise dynamic responses, the tribo-dynamic model integrates the time-varying mesh stiffness, load-sharing ratio and friction parameters. To improve the computational efficiency and guarantee the calculation precision, an improved and updated wear depth methodology is constructed in the wear prediction model. This paper demonstrates the capability of the proposed dynamic wear prediction model in the investigation of the interaction effects between gear dynamics and surface wear, allowing for the development of improved gear wear prediction tools. The obtained results indicate that the surface wear impacts the dynamic characteristics, even with slight wear. In the initial stage of wear, the friction coefficient decreases slightly, largely due to the reduction in surface roughness; but the friction force increases because of the improved dynamic meshing force. Although the initial wear depth distributions of a pinion under dynamic and static conditions are similar, the wear depth distributions under dynamic conditions becomes significantly different compared to the those under static conditions with the wear process. The maximum wear depth of a pinion under dynamic conditions is about 1.6 times as the corresponding static conditions, when the wear cycle comes to 4 × 104. Similarly, the maximum accumulative wear depth of a pinion under dynamic conditions reaches 1.2 times of that under static conditions. Therefore, the proposed dynamic wear prediction model is more appropriate to be applied to the surface wear of gears.

Research on tool wear morphology and mechanism during turning nickel-based alloy GH4169 with PVD-TiAlN coated carbide tool

Tool wear affects tool life, dimensions, etc. However, tool wear mechanism was mainly studied by the relevant references in the sharp wear stage, and tool wear morphology and mechanism were not completely understood in the initial and steady wear stage. Tool wear investigation of coated carbide tool is carried out during turning GH4169 in dry cutting. Tool wear microscopic morphology, tool wear curve, tool cutting force and tool wear mechanism are studied during turning GH4169 in the initial, steady and sharp wear stage. Tool wear mechanism in the sharp wear stage is further investigated by SEM, EDS, XPS and XRD. Doing so helps to test and improve the quality of the tool coating and substrate material, helps to gain a deep understanding of the difficult-to-machine characteristics of GH4169, and helps to guarantee the dimensional accuracy and surface quality of the workpiece. Results show that serious abrasive wear, tool nose wear and adhesive wear occurred in the whole wear stage. The tool wear rate of turning superalloy GH4169 is much faster, the cutting force increases, the tool substrate material was worn seriously. The main tool wear mechanisms are abrasive wear, adhesive wear, oxidation wear and diffusion wear. Severe abrasive wear occurred between the large amount of hard abrasive carbides in the workpiece material and the tool rake and flank faces. Ni, Fe, Cr, etc are mainly distributed in the relevant wear areas. WO3, Co3O4, Ni2O3, Fe2O3, etc indicate that oxidation wear occurred, Ni, Fe, Cr, Nb and Mo are detected across the cross-section, which means that diffusion wear has occurred.