Experimental investigation of chip plastic side flow in machining of GH4169 superalloy under high-pressure cooling

Nickel-based superalloy is a kind of typical difficult-to-cut material. Its cutting machinability is poor and chip is not easy to break. The phenomenon of chip plastic side flow has significant influence on the tool life, machining quality and efficiency in cutting process. Firstly, the influence of cutting parameters and cooling pressure on the macro morphology of chip was studied. Secondly, the influence factors of chip plastic side flow, such as cutting parameters, cooling pressure, tool wear and so on, were discussed. Finally, the influence of chip plastic side flow on the rake face of PCBN tool was analyzed. The above studies were based on the experiment of cutting nickel-based superalloy by PCBN tool under high pressure cooling and the conventional cutting experiments. The results demonstrated that the ability of chip breaking could be significantly enhanced in the condition of high pressure cooling and the chip was saw-tooth chip of short coil. According to the test results, the cutting parameters and the cooling pressure were determined when the macro morphology of the chip was better. The effects of cutting parameters, cooling pressure and tool wear on the chip plastic side flow and the cause of the groove wear of the rake face of PCBN tool were revealed. It was found that the high pressure cooling condition can reduce the wear of the chip side flow to the rake face of tool. The results can provide theory reference for the high quality and high efficiency cutting superalloy under high pressure cooling.