Ultrasonic Vibration-assisted Milling of Nickel-based High-temperature Alloy GH4169:A Study of Cutting Performance
Nickel-based superalloy GH4169 is notoriously difficult to machine,typically leading to considerable tool wear and suboptimal surface quality during conventional cutting processes.The demand for high-performance materials(such as superalloys,ceramics,composite materials,etc.)in modem industry has increased,and the processing of these materials is difficult,and conventional tools are difficult to process effectively.With the continuous development of ultrasonic technology,especially in the field of material processing,ultrasonic vibration cutting has become a hot research direction.Ultrasonic vibration cutting is an innovative machining technology that combines ultrasonic vibration with the cutting process to significantly reduce cutting forces and increase processing speed,thereby improving overall production efficiency.With the help of ultrasonic vibration,the surface roughness and defects generated in the cutting process can be reduced,and better surface quality can be obtained.Due to the reduction of cutting force and the dispersion of heat,ultrasonic vibration cutting can effectively slow the wear of the tool,thus extending the service life of the tool.This study employs both conventional cutting simulations and ultrasonic vibration cutting simulations,using metrics such as cutting stress,cutting force and cutting temperature to assess performance.Results indicate that ultrasonic vibration cutting can decrease cutting stress by up to 4.4％,cutting temperature by up to 14.2％,and cutting force by up to 50％compared to conventional methods.Orthogonal milling experiments further confirm that ultrasonic vibration milling improves the cutting performance of GH4169 by comparing cutting force,cutting temperature,surface roughness and tool wear.Through range analysis,the machining parameters are optimized,revealing that the primary factors affecting surface roughness are spindle speed,cutting depth and feed per tooth.The optimal parameters for surface roughness are identified as a spindle speed of 2 500 r/min,a feed per tooth of 0.05 mm/z and a cutting depth of 0.2 mm.In contrast,the primary factors affecting tool wear are determined to be feed per tooth,cutting depth and spindle speed.The optimal parameters for tool wear are found to be a spindle speed of 2000 r/min,a feed per tooth of 0.03 mm/z and a cutting depth of 0.2 mm.Excessive cutting depth and feed per tooth are associated with poor surface quality and significant tool wear.Thus,it is recommended that the cutting depth does not exceed 0.2 mm and the feed per tooth does not exceed 0.05 mm/z.
high temperature alloyscutting forcecutting temperaturemachining parametersmachinability
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