Analysis of Surface Residual Stress and Formation Mechanism of Metamorphic Layer in PCBN Tool Cutting Superalloy under High-pressure Cooling

doi:10.3901/JME.2022.01.231

Abstract

Abstract: Nickel-based superalloy is one of the typical difficult-to-cut materials. It is used widely in aerospace, energy, and other fields, because of its excellent mechanical properties at high temperatures. During the cutting process, severe plastic deformation of the workpiece occurs because of the combined action of cutting force and cutting heat. It leads to an uneven distribution of residual stress and metamorphic layers on the machined surface, thereby reducing the fatigue strength of the workpiece. High-pressure cooling and lubrication-assisted machining technology can effectively improve this problem. Therefore, it has important theoretical significance and practical value to study the residual stress and metamorphic layer of GH4169 under high-pressure cooling. Firstly, the temperature, mises stress, and residual stress are simulated and analysed under different cooling pressures. The residual stress under different cooling pressures by using X-ray. The influence of cooling pressure on the residual stress is analysed and compared with the simulation results. Secondly, based on the analysis of residual stress results, EDS and XRD are used to observe the microstructure of the machined surface metamorphic layer and the matrix of GH4169 for comparative analysis. Finally, the effects of cutting speed, feed rate, and cooling pressure on the thickness of the machined surface metamorphic layer are analysed. The results show that the XRD diffraction peak of the metamorphic layer on the machined surface is wider and lower than that of the matrix, indicating that the grain refinement occurs in the metamorphic layer. For the given range of parameters, the thickness of the metamorphic layer increases with the increasing cutting speed and feed rate. However, with the increase of cooling pressure, the uneven distribution of residual stress caused by thermo-mechanical coupling and plastic deformation is weakened, and the thickness of the metamorphic layer decreases.

Key words: high-pressure cooling, residual stress, metamorphic layer, grain refinement, microstructure

CLC Number:

TG501

WU Mingyang, ZHANG Yali, CHENG Yaonan, ZHANG Jianyu, CHU Weixu. Analysis of Surface Residual Stress and Formation Mechanism of Metamorphic Layer in PCBN Tool Cutting Superalloy under High-pressure Cooling[J]. Journal of Mechanical Engineering, 2022, 58(1): 231-243.

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