Experimental study of cutting-parameter and tool life reliability optimization in inconel 625 machining based on wear map approach

As a result of its excellent properties, nickel-base superalloy has been widely used in the manufacture of shaft-disc-type components for aeroengines. However, tool wear and short tool life are prominent problems related to the machining process, because of the poor thermal conductivity, high hardness, and strong cohesiveness of nickel-base superalloy. Therefore, optimization of both the processing parameters and tool life reliability is attracting increasing research attention. In this study, coated carbide tools are used in turning tests of Inconel 625 superalloy. The wear morphologies and mechanisms of these tools under different parameters are analyzed, and a two-dimensional tool wear map is constructed. The influence of the cutting parameters on the workpiece surface roughness and flank wear is analyzed with consideration of the wear map, so as to determine the optimal cutting parameters. On this basis, a complete tool life experiment is performed, and a tool life distribution model and tool life reliability model are established to facilitate tool life reliability evaluation under the optimal parameters. These findings provide theoretical support for process optimization in Inconel 625 machining.