LAUSR

Abstract Nickel-based superalloy (GH4169) has been widely used to manufacture critical parts in the aerospace field due to its excellent properties, such as high thermal strength, excellent thermal stability, and fatigue resistance. However, it is a difficult-to-machine material because of its inherent properties. Large cutting forces, high cutting temperatures, severe tool wear, and other problems are common in the cutting process. In this study, to improve the cutting performance of GH4169, micro - textured tools were used to cut GH4169 in spray cooling. The micro-texture morphology, size parameters, and cutting parameters of the tools were studied. Five micro-textured tools with different morphology were designed. The finite element simulation models of micro-textured tools turning GH4169 were established by DEFORM, and cutting simulation analysis of the five micro-textured tools was carried out. The shape of the micro-textured tool with the most minor cutting force was selected. Furthermore, based on the optimized shape, the micro-textured tools with different size parameters of the shape were designed and simulated. The range analysis and genetic optimization algorithm were used to analyze the simulation results, and the optimal micro-texture size parameters with the minimum cutting force were obtained. Then, based on the optimized size parameters, different cutting parameters of the micro-textured tool cutting GH4169 were designed and simulated, and the range algorithm was used to optimize the cutting parameters. Finally, the micro-textured tools for cutting experiments were manufactured and the simulations were verified. It provides a guiding basis for the high-efficiency machining of GH4169 and the design and application of microtextured tools.