Since the flank has an important influence on the surface of a workpiece, and as microstructure flaws of the surface metamorphic layer are a key factor that affects the service performance of a part, this work studied the influence of flank wear on the microstructure characteristics of the metamorphic layer under the conditions of high-pressure cooling. First, Third Wave AdvantEdge was used to create a simulation model of cutting GH4169 using tools with different flank wears under high-pressure cooling. The simulation findings emphasized the impact of flank wear width (VB) on the cutting force, cutting temperature, plastic strain, and strain rate. Second, an experimental platform was established for cutting GH4169 under high-pressure cooling, and the cutting force during the machining process was recorded in real time and compared with the simulation results. Finally, an optical microscope was used to observe the metallographic structure of the GH4169 workpiece section. The microstructure characteristics of the workpiece were analyzed using a scanning electron microscope (SEM) and electron backscattered diffraction (EBSD). It was discovered that, as the flank wear width increased, so did the cutting force, cutting temperature, plastic strain, strain rate, and plastic deformation depth. The relative error between the simulation results of the cutting force and the experimental results was within 15%. At the same time, near the surface of the workpiece, there was a metamorphic layer with fuzzy grain boundaries and refined grain. With an increase in flank wear width, the thickness of the metamorphic layer increased from 4.5 μm to 8.7 μm and the grain refinement intensified. The high strain rate promoted recrystallization, which caused an increase in the average grain boundary misorientation and high-angle grain boundaries, as well as a reduction in twin boundaries.
The effect of flank wear on the cutting process of PCBN tool machining GH4169 superalloy under high-pressure cooling conditions was studied in this article. First of all, the cutting models of different flank wear under conventional cooling and coolant pressure of 50bar were established by the Third Wave AdvantEdge. Secondly, under the same wear state, the author compared the simulation results of high-pressure cooling with that of conventional cooling. Simultaneously, the influence of flank wear width(VB) on cutting force, the temperature of the machining zone, and surface residual stress during coolant pressure of 50bar was discussed. Finally, the PCBN tool life forecasting model was established by a method of the GA-BP neural network, and then the generalization ability of the forecasting model was evaluated by 6-fold cross-validation method. The results show that high-pressure cooling cutting effectively grows down the cutting force and temperature generated during the cutting process, and with the rise of flank wear width(VB), the cutting force, the temperature of the machining zone, and residual stress values show an increasing trend. The main reason is that the aggravated flank wear results in strong extrusion friction and plastic deformation in the contact area between the tool and the workpiece, which has different effects on the force-thermal characteristics.
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