Improving tool life in multi-axis milling of Ni-based superalloy with ball-end cutter based on the active cutting edge shift strategy

Luo, Ming; Luo, Huan; Zhang, Dinghua; Tang, Kai

doi:10.1016/j.jmatprotec.2017.09.010

Cited by 59 publications

(12 citation statements)

References 24 publications

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“…Thermal barrier coating technology is widely used in hot components such as turbine blades, combustion chambers, and air inlets in a combined propulsion system [22]. MCrAlY (M = Ni, Co, or NiCo), a high temperature-and oxidation-resistant alloy, is mainly used as the metal adhesive layer, yttria-stabilized zirconia (YSZ) is mainly used as the ceramic thermal insulation coating in the surface layer, and the double-layer structure is usually adopted in practical applications [23,24]. Air plasma spray (APS) [25] or physical vapor deposition [26] are generally taken as the spraying process.…”

Section: Overviewmentioning

confidence: 99%

Thermal Protection System and Thermal Management for Combined-Cycle Engine: Review and Prospects

et al. 2019

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Combined-cycle engine is a potential propulsion system for hypersonic aircraft. To ensure long-term, normal operation of combined-cycle engine under the harsh environment of high thermal load, it is of great significance to study the thermal protection and management of the propulsion system. In this study, the objective and development status of thermal protection and thermal management systems for the combined-cycle propulsion system were described. The latest research progresses of thermal protection, thermal barrier coating, and thermal management system of the combined-cycle propulsion system were summarized. Moreover, the problems and shortcoming in current researches were summarized. In addition, a prospect for the future development of thermal protection and management of the combined-cycle propulsion system was presented, pointing out a direction of great value and vital research significance to thermal protection and management of the combined-cycle propulsion system.

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Section: Overviewmentioning

confidence: 99%

Thermal Protection System and Thermal Management for Combined-Cycle Engine: Review and Prospects

et al. 2019

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“…It was proven, both by FEM simulation (Finite Element Method) and during the test experiment that the least strain of a 2 mmthick wall was obtained when applying the angles of 15 and 45 degrees. In the study [4], the new milling strategy for free surfaces was proposed to increase the cutting edge durability while milling the hard-to-machine nickelbased alloy (GH4169). Such a strategy consists in the active control of the ball-shaped cutter working part involvement.…”

Section: Introductionmentioning

confidence: 99%

Highly Efficient Milling on the Example of Selected Machining Strategies

Zaleski¹,

Matuszak²,

Zyśko³

2020

Adv. Sci. Technol. Res. J.

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The pursuit to achieve a broadly defined optimisation of the manufacturing processes imposes the use of the increasingly innovative machining methods. The increase of the machining efficiency, assuring a high surface quality as well as precision of dimensions and shapes, necessitates the search for new methods to meet the demanding requirements, apart from the development of materials used for the working parts of tools, wear-resistant coatings or improvement of the cutting tool point geometry. One of the methods to improve forming by machining is the optimisation of the machining strategy during the manufacture of the components having complex shapes. The progress in this field is particularly noticeable along with development of the software for machining on multi-axis machines. This article presents the results of tests for the impact of machining strategy on passive force, cutting torque, material removal rate, topography of the obtained surface and the shape of chip resulting from the aluminium alloy milling. The tests were performed by comparison of the classic strategy available in the NXCAM system to the iMachining technology.

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“…Many methods are used to improve tool performance. Luo [8] changed the multi-axis milling strategy based on shifting the active cutting edge to average the wear of the cutting edge on the cutter, thus prolonging the tool life. Changing the lubrication method can also increase the tool life.…”

Section: Introductionmentioning

confidence: 99%

Failure and Control of PCBN Tools in the Process of Milling Hardened Steel

Wang

Zhou

et al. 2019

Metals

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The polycrystalline cubic boron nitride (PCBN) milling tool can be used in the mold industry to replace cemented carbide tools to improve machining efficiency and quality. It is necessary to study the tool wear and failure mechanism to increase machining efficiency and extend tool life. Cr12MoV is used to analyze the failure form of PCBN tools in the interrupted cutting of hardened steels at low and high speed conditions in milling experiments. Experimental results show that the failure forms of PCBN tools include chipping and flank wear at low speed, and the failure modes at high speed are flank wear, the surface spalling of the rake face, and the fatigue failure on the flank face. The failure mechanism of different failure forms is analyzed by observing the surface morphology of the tool and using the theory of fracture mechanics. The results show that a high cutting speed should be selected to avoid the early damage of low speed and achieve better application of PCBN tools. At high cutting speed, tool failure is mainly caused by mechanical wear, diffusion wear, and oxidation wear. Moreover, a fatigue crack will occur at the cutting edge on the chamfered tool under thermal-mechanical coupling because of the intergranular fracture of the CBN grain and binder. A large area of accumulated fatigue damage may appear due to the influence of alternating mechanical stress and thermal stress. Finally, the control method to avoid tool failure is presented.Metals 2019, 9, 885 2 of 15 nitride (PCBN) cutting tools are the preferred tool material due to excellent mechanical properties of higher hardness strength and wear resistance than other tool materials at high temperature. They are frequently used in the turning of hard and wear-resistant materials, such as hardened steels, superalloy, and even ceramics [11][12][13][14]. Numerous studies investigate the machining performance and tool life in PCBN hard turning [15][16][17]. Progressive flank wear, micro-chipping, and tool breakage easily occur due to critical crater wear [18]. For different cutting tools and workpiece materials, cutting speed is the main factor affecting the tool life, and it usually has a critical value after which the tool life of the cemented carbide tool will be lower than the PCBN cutting tool.In recent years, scholars have focused on the research of milling using the PCBN cutting tool. The results show that with a smaller cutting force [19], better surface quality [20], and a higher volume of metal removal [21] can be obtained by using PCBN tools compared with carbide-coated tools in processing hardened steel materials.It is observed that surface roughness (Ra) is in the range of 0.2 to 0.3 µm using a PCBN ball end tool, compared with 0.4 to 0.6 µm using the cemented tungsten carbide tool, at the cutting speed of 400 m/min in the milling of DIEVAR tool steel [22]. For milling, there is still a speed below which the tool life of cemented carbide is less than the tool life of PCBN. The life of cemented carbide tools can be higher than that of PCBN to...

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Improving tool life in multi-axis milling of Ni-based superalloy with ball-end cutter based on the active cutting edge shift strategy

Cited by 59 publications

References 24 publications

Thermal Protection System and Thermal Management for Combined-Cycle Engine: Review and Prospects

Thermal Protection System and Thermal Management for Combined-Cycle Engine: Review and Prospects

Highly Efficient Milling on the Example of Selected Machining Strategies

Failure and Control of PCBN Tools in the Process of Milling Hardened Steel

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