Experimental And Simulation Research On Cutting GH4169 With PCBN Tool

Nickel-based Superalloy GH4169 is a typically difficult-to-cut material. In the cutting work of alloy material, the plastic side-flow phenomenon of plastic deformation has a greater effect on the finished surface roughness, the cutting tools’ usability and longevity, and so on. PCBN as one of the extra-hard tool material, has the potential for superalloy cutting. However, it’s difficult for chip breaking because PCBN tool doesn’t has the chip-breaking groove. So, to the application of developing PCNB tool, search on the cutting parameters and tool geometrical parameter is of great significance. Through right angle of PCBN Tool freely cut nickel-based superalloy GH4169, the present paper explore the regularity rule of cutting stress and surface quality based on the change of cutting parameter, the PCBN chamfer angles and chip morphology.Firstly, the test on the PCBN tools right-angled cutting nickel-based superalloy GH4169 was designed and the relations between cutting force and chamfer angle was analyzed with different geometrical parameters. at the same time, according to the orthogonal experiment using range and variance analysis obtain the influence of cutting parameters on cutting force. By using the multiple linear regression equation, establishs empirical prediction model of cutting force and provides a reference for subsequent research work.Secondly, focus on cutting chip side flow phenomenon in the process of research and analyze influencing factors of chip side flow and the effect of chip side flow on tool wear. Chip width increase is proportional to the feeding and negative chamfer Angle increase and is Inversely proportional to the increase of cutting speed. The more the chip width increases, the more obvious the chip side flow is, the bigger the burr size is. By the influence of the cutting parameters on the macro state and the micro parameters of the chip(chip thickness, tooth height and tooth angle) found that: vc=130m/min,f=0.1mm/r、ap=0.2mm, the macro state was the best.Thirdly, according to the data results of single factor experiment, second-order response surface forecasting model was built; the response surface analysis of different cutting parameters aspects and interaction was conducted. On the basis of the experiment data, which demonstrates the system forecasting error is below 9% and has the considerable accuracy, Taking the surface roughness as the goal, the processing optimization has reached to improve the operation efficiency and reduce the production cost.Finally, using Thirdwave Advant Edge finite element simulation software, Simulate nickel-based superalloy GH4169 cutting process micro plastic deformation and analyze the influence of negative chamfer angle and variation of cutting parameters on cutting temperature, chip morphology, equivalent stress and shear angle. And through the plastic strain rate indicator react metal Materials cutting in the shape of lateral flow phenomenon.