Optimization Of Machining Parameters For Curved Surface Made From Nickel-based Superalloy With High-speed Milling Based On Cutting Force

There are high cutting temperature, serious wear on tools and large cutting force in the process of cutting nickel-base superalloy, it makes nickel-base superalloy become a typical difficult-to-cut material. Due to the requirements of high strength and corrosion resistance, many workpieces which are used in aerospace such as turbine disks, turbine blades are made from nickel-based superalloy, but the complex geometric characteristics of these workpieces make the removal of material in the cutting process inconsistent, such changes of removal lead to fluctuations of cutting force, which impacts the vibration and deformation of process systems, ultimately affecting the quality of. So means to reduce the fluctuations of cutting force in order to improve the quality of such workpieces is needed urgently in the curved surface processing field. High-speed milling with the characteristics of high cutting speed, small cutting force provides a mean for the efficient and high-quality processing of such workpieces which have complex surfaces. This article has the purpose of optimizing the machining parameters to study cutting force, chips and surface roughness during the process of machining curved surface made from Inconel718with high-speed milling in the following aspects.Firstly this acticle studies the cutting force and its law of fluctuations during the machining process of high-speed milling, which is based on a simple curved surface made of Incone1718,exploring the law of cutting force fluctuations with spindle speed, axial depth of cut and feed rate per tooth in the process of machining curved surface made from Inconel718with high-speed milling by the method of single factor experiments, researching the influence of surface curvature, punch and feed direction of the spindle to the cutting force on processing sinusoidal surface. It is followed by optimizing the machining parameters to guarantee the fluctuations of cutting force is small during the process of machining curved surface made from Incone1718with high-speed milling. The results contribute to a better understanding of the fluctuations of cutting force when machining curved surfaces,but also provide the basis for optimizing the machining parameters during the process of machining curved surface made from Incone1718with high-speed milling.Secondly.This acticle studies the changes of chip morphology with spindle speed, axial depth of cut and feed rate per tooth through measuring the chip morphology in the process of machining curved surface made from Inconel718with high-speed milling under different conditions of process parameters. Analyzing the impact of cutting force fluctuations and area of chips to the surface roughness by using average and maximum roughness of the selected characteristic points, summarizing the relationship between cutting force and area of chips by analyzing the results. The relationship summarized is conducive to deepen the understanding of the mechanism of chip formation.Finally, this acticle selects the optimized parameters to machine a saddle surface with different geometrical characteristics for an experimental verification. The results shows a better quality when the optimized machining parameters is adopted to process the saddle surface. It is proved that the parameters optimized have some applicability when processing curved surface with different geometrical characteristics.