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<p>To address the challenging machinability of aerospace single-crystal materials and optimize processing parameters for improved surface quality, GH4169 nickel-based superalloy was chosen as the research subject, with external cylindrical turning as the machining method. A three-dimensional thermo-mechanical coupled finite element model was established using ABAQUS to analyze the evolution of Mises stress, PEEQ strain, and cutting forces. Central composite design (CCD) and response surface methodology (RSM) were employed to develop a parameter optimization model linking machining parameters with surface integrity characteristics. The results indicate that increasing spindle speed enhances residual stress while simultaneously reducing cutting forces, built-up edge, and thermal softening effects, thereby improving surface quality. Higher feed rates exacerbate residual stress and cutting forces due to increased wear on the flank face and impeded chip removal, leading to surface scoring and reduced plastic strain. Larger back depths of cut expand the cutting area, significantly increasing cutting forces, but reducing residual stress and plastic strain. Response surface analysis revealed an R<sup>2</sup>value greater than 0.98, demonstrating strong optimization capability. The optimized parameter range, including <i>f</i> = 0.15 ± 0.02&#xa0;mm/r, <i>a</i><sub>p</sub> = 0.20 ± 0.05&#xa0;mm, <i>n</i> = 550 ± 30&#xa0;r/min, greatly improves machining efficiency and workpiece quality, providing effective guidance for high-precision turning of GH4169.</p> Graphical Abstract <p></p>

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Optimization of Cutting Parameters and Simulation Study for Outer Diameter Turning of Nickel-Based Superalloy GH4169

  • 期刊论文

  • 发表日期：

    2025年8月14日

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  • Jinbao Feng,
  • Xinping Liu,
  • Zeya Li,
  • Renjie Zhou,
  • Pengyu Liu,
  • Pengfei Liu

摘要

To address the challenging machinability of aerospace single-crystal materials and optimize processing parameters for improved surface quality, GH4169 nickel-based superalloy was chosen as the research subject, with external cylindrical turning as the machining method. A three-dimensional thermo-mechanical coupled finite element model was established using ABAQUS to analyze the evolution of Mises stress, PEEQ strain, and cutting forces. Central composite design (CCD) and response surface methodology (RSM) were employed to develop a parameter optimization model linking machining parameters with surface integrity characteristics. The results indicate that increasing spindle speed enhances residual stress while simultaneously reducing cutting forces, built-up edge, and thermal softening effects, thereby improving surface quality. Higher feed rates exacerbate residual stress and cutting forces due to increased wear on the flank face and impeded chip removal, leading to surface scoring and reduced plastic strain. Larger back depths of cut expand the cutting area, significantly increasing cutting forces, but reducing residual stress and plastic strain. Response surface analysis revealed an R2value greater than 0.98, demonstrating strong optimization capability. The optimized parameter range, including f = 0.15 ± 0.02 mm/r, ap = 0.20 ± 0.05 mm, n = 550 ± 30 r/min, greatly improves machining efficiency and workpiece quality, providing effective guidance for high-precision turning of GH4169.

Graphical Abstract