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<p>Nickel-based high-temperature alloys are widely used in various industries due to their excellent properties, but they face significant challenges in processing performance. Ceramic tools are ideal materials for processing nickel-based high-temperature alloys because of their high hardness. Dry intermittent turning of the nickel-based superalloy GH4169 was conducted in this paper, and the cutting performance of circular ceramic tools and rhombic ceramic tools were compared. Additionally, machine tool energy consumption, machined surface roughness, cutting temperature, ceramic tool life, and flank wear distance were measured. The optimal cutting parameters were selected by analyzing the experimental data. The research results showed that machine tool energy consumption increases as cutting speed and cutting distance increase, and it is also associated with tool geometry. Rhombic ceramic tools exhibit lower machine tool energy consumption, while circular ceramic tools perform better in terms of tool life. During the full life cycle of ceramic tools, the machine energy consumption of rhombic ceramic tools is 9.6% lower than that of round ceramic tools. The wear forms and wear mechanisms of ceramic tools were obtained by scanning electron microscopy (SEM) and energy dispersion spectroscopy (EDS). Adhesive wear, notch wear and diffusion wear are the wear mechanisms of round ceramic tools. Ceramic tools can also be worn and damaged due to impact and thermal stress. By analyzing the wear distance of the flank face, the optimal cutting parameters are determined as follows: cutting speed <i>v</i><sub><i>c</i></sub> = 110 m/min, feed rate <i>f</i><sub><i>r</i></sub> = 0.10 mm/r, and cutting depth <i>a</i><sub><i>p</i></sub> = 0.10 mm. Under the optimal parameters conditions, the tool life of 6160(R) is 50% and 12.5% longer than those of the other two round ceramic tools respectively.</p>

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Cutting performance and wear mechanism of SiAlON ceramic cutting tools for intermittent turning of GH4169

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • Yue Meng,
  • Haijun Sun,
  • Shujiang Sun,
  • Liqing Liu,
  • Yancui Jiang,
  • Shiliang Wei

摘要

Nickel-based high-temperature alloys are widely used in various industries due to their excellent properties, but they face significant challenges in processing performance. Ceramic tools are ideal materials for processing nickel-based high-temperature alloys because of their high hardness. Dry intermittent turning of the nickel-based superalloy GH4169 was conducted in this paper, and the cutting performance of circular ceramic tools and rhombic ceramic tools were compared. Additionally, machine tool energy consumption, machined surface roughness, cutting temperature, ceramic tool life, and flank wear distance were measured. The optimal cutting parameters were selected by analyzing the experimental data. The research results showed that machine tool energy consumption increases as cutting speed and cutting distance increase, and it is also associated with tool geometry. Rhombic ceramic tools exhibit lower machine tool energy consumption, while circular ceramic tools perform better in terms of tool life. During the full life cycle of ceramic tools, the machine energy consumption of rhombic ceramic tools is 9.6% lower than that of round ceramic tools. The wear forms and wear mechanisms of ceramic tools were obtained by scanning electron microscopy (SEM) and energy dispersion spectroscopy (EDS). Adhesive wear, notch wear and diffusion wear are the wear mechanisms of round ceramic tools. Ceramic tools can also be worn and damaged due to impact and thermal stress. By analyzing the wear distance of the flank face, the optimal cutting parameters are determined as follows: cutting speed vc = 110 m/min, feed rate fr = 0.10 mm/r, and cutting depth ap = 0.10 mm. Under the optimal parameters conditions, the tool life of 6160(R) is 50% and 12.5% longer than those of the other two round ceramic tools respectively.