An airplane has about 6-million components and parts, mainly the engine, undercarriage, constructions and so on. Among them, nickel base materials are widely used, including engine, cartridge receiver, compressor drum and other industries application, such as energy, petrochemical industry, mould, etc. Nickel base alloy, with anti-corrosion and thermo stability, has good mechanical properties under high temperature. Since 1950s, due to the development of precision casting technology, a series of cast nickel base super-alloy with high strength has been developed, namely the super-alloy complying with the above conditions. In recent years, with the changing of military and civil aerospace, the usage amount of nickel base super-alloy also increases along with the date. This research mainly used Waspaloy of nickel base material to do cutting research and uses regression analysis to find significant factor of cutting tool's life, and performs the optimization experiment. The cutting research mainly uses TiAlN to coat cutting tools. In the conclusion, it discusses main factors that influence the tool life, such as the cutting speed, depth, feed rate and so on. Finally it establishes tool life formula with regression analysis method, in this case when cutting speed V = 30.77 m/min and cutting depth dp = 0.0367mm, the minimum wear prediction can be obtained.

Nickel-based materials are widely used in making engine parts, compressor rotors and energy production. Nickel-based materials are resistant to corrosive conditions, and have a high strength in extreme temperatures. They also feature satisfactory mechanical properties in extreme heat. The use of these nickel-based super-alloys is on the rise every day as they have been widely used in military and civilian aeronautical industries in recent years. For this reason, it was the intention of this study to do optimised cutting experiments on Waspaloy in order to identify the significant factors which have impact on the tool life of cutting tools using the response surface methodology (RSM) in regression analysis. Several factors were found in the results that had significant impact on the machining tools’ life, including machining speed, depth, and feed rate. Finally, a regression analysis was adopted to establish a formula for calculating the service life of cutting tools. It was found that the minimum wear was achieved with the cutting speed at V = 33.21 m/min, cutting depth at dp = 0.0367 mm and feed per tooth at Ft = 0.367 mm/tooth.

Nickel-based materials are widely used in engines, housings, and compressor rotors. They are also used in other industries, such as energy, petrochemicals, and tool and die making. Nickel-based alloys have a high tolerance to high temperatures and superior anti-corrosion characteristics while maintaining good mechanical properties. Owing to the development of precision casting technology in the late 1950s, a series of highly intensive cast nickel-based superalloys with these properties have been developed. With the rapid changes in the military and civil space industries in recent years, the use of nickel-based superalloys is increasing. In this study, we mainly use Waspaloy as a nickel-based material to study cutting; we use regression analysis to find the significant factors affecting cutting force and surface accuracy and then perform an optimization experiment. A TiAlN-coated tool is mainly used in the study of cutting. We conclude that the significant factors affecting the cutting force among the experimental conditions are the cutting depth and feed rate per tooth and that the significant factors affecting the surface accuracy are the feed rate per tooth and cutting speed. When the cutting depth dp increases from 0.1 to 0.3 mm, the tool wear increases by 94.1%, and when the cutting speed V c increases from 30 to 40 m/min, the tool wear decreases by 2.17%. 1. Tool form: R200-024A32-16M. 2. Machining parameters: cutting speed V c = 40 mm/min; cutting depth dp = 0.3 mm.