On the Anisotropic Milling Machinability of DD407 Single Crystal Nickel-Based Superalloy

The DD407 single crystal Ni-based superalloy with a face-centered cubic structure exhibits strong anisotropic characteristics. In order to reveal the material chip formation mechanism and the impact effect of crystal orientations on the materials' milling machinability, a combination of experimental observations and theoretical analysis were applied in this study. Considering the resolved shear stress and slip system theories, a fundamental theoretical explanation of the milling force and surface quality along different crystal directions on the (001) crystal plane of the DD407 single crystal Ni-based superalloy was proposed based on a previously constructed anisotropic milling model. Our work in this research verifies that [110] crystal direction on the (001) crystal plane of the DD407 single crystal Ni-based superalloy is the most optimal feeding direction during milling, taking into account surface roughness and morphology, slot bottom plastic deformation, work hardening, and chip edge burr feature.

Automated summary

In this study, a combination of experimental observations and theoretical analysis was used to investigate the milling machinability of DD407 single crystal Ni-based superalloy. By considering resolved shear stress and slip system theories, a theoretical explanation for the milling force and surface quality along different crystal orientations was proposed. Through validation, the most optimal feeding direction was determined, taking multiple machining factors into account.