Influence of tool wear on machining surface integrity of GH4169
XIE Xiaoying1, ZHU Haoyang2, ZHANG Yinxia2
1. School of Electrical and Information Engineering, Zhengzhou University, Zhengzhou 450001, Henan, China; 2. School of Mechanical and Power Engineering, Zhengzhou University, Zhengzhou 450001, Henan, China
Abstract:Surface integrity is an important parameter to evaluate the machining quality of mechanical parts,and it has a direct impact on the service performance of mechanical parts(including corrosion resistance,wear resistance and fatigue performance). In view of the poor surface integrity when high-speed machining superalloys(also known as heat resistant superalloys),high-speed machining experiments of superalloy GH4169 were carried out to study the influence of tool wear on the surface integrity (including surface roughness,microhardness,residual stress,and microstructure) of high-speed machining superalloy GH4169,improve the surface integrity of superalloys,and provide theoretical support for high-quality machining of superalloys in the future. The experimental results show that the surface roughness Ra reaches the minimum value(0.26 μm) when the flank wear is 0.1 mm. When the flank wear ranges from 0 to 0.3 mm,the average surface microhardness obtained by high-speed cutting superalloy GH4169 is 462HV-551HV,the average surface residual stress is -1 132--651 MPa. The thickness of plastic deformation layer is positively related to the tool wear. When the cutting parameters are cutting speed of 75 m/min,feed rate of 0.1 mm/r,and cutting depth of 0.5 mm,the thickness of plastic deformation layer is 18-56 μm when the tool wear ranges from 0 to 0.3 mm. In general,the surface microhardness and compressive residual stress increase with the increase of tool wear. The surface roughness decreases first and then increases with the increase of tool wear. Excessive tool wear causes poor processing quality. Appropriate tool wear can obtain better surface roughness and surface quality. It is necessary to improve the surface integrity of superalloy GH4169 by controlling tool wear.
[1] THAKUR A,GANGOPADHYAY S. State-of-the-art in surface integrity in machining of nickel-based super alloys[J]. International Journal of Machine Tools and Manufacture,2016,100:25. [2] 尉文超,张宵璐,金国忠,等. 硫化物改质对20MnCr5齿轮钢夹杂物和切削性能的影响[J]. 钢铁,2022,57(5):99.(YU W C,ZHANG X L,JIN G Z,et al. Influence of sulfide modification on inclusions and cutting properties of 20MnCr5 gear steel[J]. Iron and Steel,2022,57(5):99.) [3] LIAO Z,MONACA A,MURRAY J,et al. Surface integrity in metal machining—Part I:Fundamentals of surface characteristics and formation mechanisms[J]. International Journal of Machine Tools and Manufacture,2021,162:103687. [4] 杜劲,刘战强,张入仁,等. 镍基高温合金高速铣削加工表面完整性[J]. 中南大学学报(自然科学版),2012,43(7):2593.(DU J,LIU Z Q,ZHANG R R,et al. Surface integrity on high speed milling Ni-based superalloy[J]. Journal of Central South University(Natural Science),2012,43(7):2593.) [5] 丁文锋,李敏,李本凯,等. 难加工金属材料磨削加工表面完整性研究进展[J]. 航空材料学报,2021,41(4):36.(DING W F,LI M,LI B K,et al. Recent progress on surface integrity of grinding difficult-to-cut metal materials[J]. Journal of Aeronautical Materials,2021,41(4):36.) [6] 张银霞,郜伟,康仁科,等. 单晶硅片磨削损伤的透射电子显微分析[J]. 半导体学报,2008,29(8):1552.(ZHANG Y X,GAO W,KANG R K,et al. TEM observation on the ground damage of monocrystalline silicon wafers[J]. Journal of Semiconductors,2008,29(8):1552.) [7] 陈涛,刘献礼,李素燕,等. 高速硬切削加工表面白层形成机理研究[J]. 机械工程学报,2015,51(23):182.(CHEN T,LIU X L,LI S Y,et al. Mechanism of white layer formation on machined surface of high-speed hard machining[J]. Journal of Mechanical Engineering,2015,51(23):182.) [8] XU D,LIAO Z,AXINTE D,et al. A novel method to continuously map the surface integrity and cutting mechanism transition in various cutting conditions[J]. International Journal of Machine Tools and Manufacture,2020,151:103529. [9] M′SAOUBI R,AXINTE D,HERBERT C,et al. Surface integrity of nickel-based alloys subjected to severe plastic deformation by abusive drilling[J]. CIRP Annals,2014,63(1):61. [10] 赵振业. 高强度合金抗疲劳应用技术研究与发展[J]. 中国工程科学,2005,7(3):90.(ZHAO Z Y. Investigation and development status of the application technology to improve fatigue behavior of high strength alloy[J]. Engineering Science,2005,7(3):90.) [11] 郭东明,孙玉文,贾振元. 高性能精密制造方法及其研究进展[J]. 机械工程学报,2014,50(11):119.(GUO D M,SUN Y W,JIA Z Y. Methods and research progress of high performance manufacturing[J]. Journal of Mechanical Engineering,2014,50(11):119.) [12] 杨振朝,张定华,姚倡锋,等. TC4钛合金高速铣削参数对表面完整性影响研究[J]. 西北工业大学学报,2009,27(4):538.(YANG Z C,ZHANG D H,YAO C F,et al. Effects of high-speed milling parameters on surface integrity of TC4 titanium alloy[J]. Journal of Northwestern Polytechnical University,2009,27(4):538.) [13] 武导侠,张定华,姚倡锋. GH4169高温合金车削表面完整性对疲劳性能的影响[J]. 航空材料学报,2017,37(6):59.(WU D X,ZHANG D H,YAO C F. Effect of surface integrity of turned GH4169 superalloy on fatigue performance[J]. Journal of Aeronautical Materials,2017,37(6):59.) [14] 金洁茹,张显程,涂善东,等. 车削速度对GH4169加工表面完整性的影响[J]. 中国表面工程,2015,28(3):108.(JIN J R,ZHANG X C,TU S D,et al. Effects of cutting speed on machining surface integrity of GH4169[J]. China Surface Engineering,2015,28(3):108.) [15] 赵彪,王欣,陈涛,等. 航空航天难加工材料切削加工过程模拟与智能控制综述[J]. 航空制造技术,2023,66(3):14.(ZHAO B,WANG X,CHEN T,et al. A review on cutting process simulation and intelligent control of difficult-to-cut materials in aerospace industry[J]. Aeronautical Manufacturing Technology,2023,66(3):14.) [16] 于忠光,浦荣,韩占龙,等. PVD 涂层刀具铣削GH4169 高温合金薄壁件性能对比[J]. 航空制造技术,2023,66(3):78.(YU Z G,PU R,HAN Z L,et al. Performance comparison of PVD coated cutting tools in milling of GH4169 superalloy thin-walled workpiece[J]. Aeronautical Manufacturing Technology,2023,66(3):78.) [17] 李锋,李亚胜,刘维伟,等. GH4169高速铣削加工残余应力分布规律试验[J]. 表面技术,2016,45(12):199.(LI F,LI Y S,LIU W W,et al. Distribution law test of residual stress in high-speed milling GH4169[J]. Surface Technology,2016,45(12):199.) [18] 邹雄,梁益龙,吴泽丽,等. 磨料水射流喷丸对渗碳GDL-1钢表面完整性及疲劳性能的影响[J]. 中国表面工程,2017,30(2):41(ZOU X,LIANG Y L,WU Z L,et al. Effects of abrasive waterjet peening on surface integrity and fatigue properties of carburizing GDL-1 steel[J]. China Surface Engineering,2017,30(2):41.) [19] 任学冲,陈利钦,刘鑫贵,等. 表面超声滚压处理对高速列车车轴钢疲劳性能的影响[J]. 材料工程,2015,43(12):1.(REN X C,CHEN L Q,LIU X G,et al. Effects of surface ultrasonic rolling processing on fatigue properties of axle steel used on high speed train[J]. Journal of Materials Engineering,2015,43(12):1.) [20] 李瑞锋,张德远,程明龙. 高强钢大直径内螺纹超声滚压强化技术[J]. 中国表面工程,2014,27(2):63.(LI R F,ZHANG D Y,CHENG M L. High-strength steel large-diameter internal thread strengthening by ultrasonic burnishing technology[J]. China Surface Engineering,2014,27(2):63.) [21] 张海宝,刘福斌,李花兵,等. 冷却速率对N06625合金凝固过程微观偏析的影响[J]. 中国冶金,2022,32(12):48.(ZHANG H B,LIU F B,LI H B,et al. Effect of cooling rate on microsegregation during solidification of N06625 alloy[J]. China Metallurgy,2022,32(12):48.) [22] 杨杰,刘光旭,王文莹,等. 热挤压对FGH96镍基粉末高温合金微观组织的影响[J]. 中国冶金,2021,31(8):40.(YANG J,LIU G X,WANG W Y,et al. Effect of hot extrusion on microstructure for nickel-based superalloy FGH96[J]. China Metallurgy,2021,31(8):40.) [23] 谷雨,杨树峰,赵朋,等. 镍基高温合金GH4738的凝固偏析和碳化物析出行为[J]. 中国冶金,2021,31(7):13.(GU Y,YANG S F,ZHAO P,et al. Solidification segregation and carbide precipitation behavior of nickel-based superalloy GH4738[J]. China Metallurgy,2021,31(7):13.) [24] 王林珠,李翔,刘录凯,等. 镍基高温合金中非金属夹杂物成分和特征控制[J]. 中国冶金,2021,31(5):32. (WANG L Z,LI X,LIU L K,et al. Control on composition and characteristics of non-metallic inclusions in nickel-base superalloy[J]. China Metallurgy,2021,31(5):32.) [25] 郑宏波,杨树峰,陈正阳,等. 优质GH4738合金棒材夹杂物研究[J]. 中国冶金,2018,28(增刊1):41.(ZHENG H B,YANG S F,CHEN Z Y,et al. Study on inclusions of high quality GH4738 alloy bar[J]. China Metallurgy,2018,28(s1):41.) [26] 黎立璋. 45钢圆钢热顶锻开裂原因分析及改进措施[J]. 轧钢,2020,37(2):50.(LI L Z. Causes analysis of hot heading cracking of 45 steel round bar and its countermeasures[J]. Steel Rolling,2020,37(2):50.) [27] 欧阳鑫,胡昕明,孙殿东,等. 微观组织对16MnDR钢板韧脆转变温度与无塑性转变温度的影响[J]. 轧钢,2021,38(6):31. (OUYANG X,HU X M,SUN D D,et al. Effect of microstructure on FATT and NDT of 16MnDR plate[J]. Steel Rolling,2021,38(6):31.) [28] 李广龙,赵坦,原思宇,等. 复合轧制工艺对SM45钢组织性能的影响[J]. 轧钢,2016,33(5):11.(LI G L,ZHAO T,YUAN S Y,et al. Effects of clad rolling technology on microstructure and properties of SM45 steel[J]. Steel Rolling,2016,33(5):11.) [29] 李旭. Q690E高强度工程机械用钢冲击韧性分析[J]. 轧钢,2018,35(4):22.(LI X. Analysis of impact toughness of Q690E high strength engineering machinery steel[J]. Steel Rolling,2018,35(4):22.) [30] 李斯文,张贵杰,胡徳红,等. TG480QZ汽车传动轴用钢组织性能的研究[J]. 轧钢,2019,36(3):22.(LI S W,ZHANG G J,HU D H,et al. Study on microstructure and mechanical properties of TG480QZ automobile driving shaft steel[J]. Steel Rolling,2019,36(3):22.) [31] 肖斌,吴雨沁,刘轶. 基于第一性原理计算的镍基单晶高温合金掺杂的机器学习研究[J]. 上海金属,2020,42(3):97.(XIAO B,WU Y Q,LIU Y. Machine learning on doping of nickel-base single crystal superalloy based on first-principles calculation[J]. Shanghai Metals,2020,42(3):97.) [32] 马天军,金鑫,赵玉才,等. 直径2 000 mm超大型高温合金涡轮盘的制造工艺研究[J]. 上海金属,2009,11(5):42.(MA T J,JIN X,ZHAO Y C,et al. Research on production of ø2 000 mm super large gas turbine disk of superalloy[J]. Shanghai Metals,2009,11(5):42.) [33] 洪笑宇,刘青欢,徐裕来,等. 新型镍基高温合金1 100 ℃氧化行为的研究[J]. 上海金属,2018,40(5):55.(HONG X Y,LIU Q H,XU Y L,et al. Oxidation behavior of a new ni-based superalloy at 1 100 ℃[J]. Shanghai Metals,2018,40(5):55.) [34] KLUMPP A,MAIER S,CHEN H,et al. Influence of work-hardening on fatigue crack growth,effective threshold and crack opening behavior in the nickel-based superalloy Inconel 718[J]. International Journal of Fatigue,2018,116:257. [35] International Organization for Standardization. ISO 3685—1993,Tool-Life Testing with Single-Point Turning Tools[S]. Switzerland:IX-ISO,1993-11-15.