Influencing of microparticle on surface morphology during broaching FGH 4097 with quasi-two-dimensional simulation model

Abstract

Nickel-based alloys are widely used in aerospace and other fields due to their excellent mechanical properties. However, nickel-based superalloys typically contain hard phases that impact their machinability and the integrity of the machined surface. To accurately predict the processing state of nickel-based superalloy components and optimize the processing technology, the accurate modeling of heterogeneous materials is very important. This study innovatively proposed an accurate multi-scale material model that incorporates microscopic hard phase particles into a macroscopic material model and applies this material model to the cutting dynamics simulation analysis of FGH 4097. Through comparison, it is found that the model established in this paper can greatly improve the accuracy of simulation prediction. Compared to conventional simulation models, the model proposed in this paper effectively illustrates the impact of microscopic particles in materials on the cutting process. The experimental results show that the accuracy of this model in predicting cutting force and temperature is 85.6 % and 91.7 % respectively. This model effectively enhances the prediction accuracy of surface roughness and delves into the potential mechanism of hard phases during the work-hardening process, offering new insights into the understanding and control of the machining process. In summary, the multi-scale material model developed in this study has great potential for analyzing the impact of material micro-particles on macro-cutting performance.