On machining K417 superalloy with sliding self-propelled rotary tools: simulation and experimental investigation

• Published in: International journal of advanced manufacturing technology 2023-05, Vol.126 (3-4), p.1669-1680
• Main Authors: He, Wenbo, Xue, Zhongling, Guo, Rang, Chen, Ni
• Format: Article
• Language: English
• Subjects: Advanced manufacturing technologies; CAE) and Design; Computer-Aided Engineering (CAD; Coordinates; Cutting parameters; Cutting speed; Cutting wear; Engineering; Experiments; Feed rate; Friction; Inclination angle; Industrial and Production Engineering; Mathematical analysis; Mechanical Engineering; Media Management; Original Article; Rake angle; Simulation; Sliding; Substrates; Superalloys; Surface roughness; Temperature distribution; Titanium alloys; Turning (machining); Wear resistance
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-11218-2

Rotary tools are increasingly being used in the cutting of superalloy due to their superior wear resistance and long life, while the sliding self-propelled rotary tools are the most widely used due to their simple structure and high reliability. In this study, the relationship between tool shear angle and inclination angle was analyzed by building a 3D coordinate system for the blade and finding an analytical relationship between tool rake angle and inclination angle. The simulation of the cutting process of K417 superalloy by sliding self-propelled rotary tools was used to investigate the impact of inclination angle and cutting parameters on cutting temperature. The results showed that turning temperature of sliding self-propelled tool decreased and then increased with increasing inclination angle. The blade cutting temperature increased with the increase of feed rate and depth of cut but had less impact on the blade temperature distribution. With increasing cutting speed, the blade cutting temperature first decreased and then increased, while the blade temperature distribution spread. Turning experiments on K417 superalloy showed that the machined surface roughness increased with increasing feed rate and depth of cut. However, with an increase of cutting speed, machined surface roughness first decreased and then increased. When cutting K417 superalloy with a p  = 0.5 mm, v c  = 90 m/min, and f = 0.1 mm/r, the flank face did not show substrate shedding until after 150 m of cutting and reached the set maximum wear width. The results showed that the cutting properties of self-propelled rotary tools were significantly improved as comparing with conventional tools.