Tool wear characteristics analysis of cBN cutting tools in high-speed turning of Inconel 718

Nickel-based superalloy is a critical material for turbine engine components in the aerospace application, but the poor machinability and low machining efficiency have further hampered it to be used widely. Cubic boron nitride (cBN), having extreme hardness and chemical inertness, is the potential candidate to process superalloys. In this paper, we systematically investigated the tool wear characteristic of cBN at different cutting speeds in dry turning of Inconel 718 by experiments and FEM simulations. The FEM model with initial flank wear land (VB) was established and validated. Effects of cutting speeds (200-400 m/min) on cBN tool life and wear mechanisms were systematically investigated. Effects of tool flank wear on cBN tool cutting edge temperature field and Inconel 718 machined surface layer stress distribution were analyzed by FEM simulations.

Automated summary

Nickel-based superalloy is a critical material in aerospace for turbine engine components, but its poor machinability and low efficiency hinder its wide use. Cubic boron nitride (cBN) is a potential candidate with extreme hardness and inertness to process superalloys. This study systematically investigated the wear characteristic of cBN at different cutting speeds during the dry turning of Inconel 718 through experiments and FEM simulations. The effects of cutting speeds on cBN tool life and wear mechanisms were examined, and FEM simulations analyzed the influence of tool wear on the cutting edge temperature field and surface layer stress distribution of Inconel 718.