Journal of South China University of Technology(Natural Science) >

2025 , Vol. 53 >Issue 5: 32 - 44

DOI: https://doi.org/10.12141/j.issn.1000-565X.240390

Mechanical Engineering

Mechanism of Saw Tooth-Shaped Chip Formation in Cast & Wrought High-Temperature Alloy GH4198

  • JIN Qichao ,
  • LI Jun ,
  • WANG Liangliang ,
  • TAN Haibing ,
  • LI Fulin ,
  • FU Rui ,
  • MENG Lingchao ,
  • GUO Lei
Expand
  • 1.Key Laboratory of Road Construction Technology and Equipment of MOE，Chang’an University，Xi’an 710064，Shaanxi，China
    2.AECC Xi’an Aero-Engine Ltd. ，Xi’an 710021，Shaanxi，China
    3.Sichuan Gas Turbine Establishment，Aero Engine Corporation of China，Chengdu 610500，Sichuan，China
    4.Gaona Aero Material Co. ，Ltd. ，Beijing 100081，China
靳淇超（1986—），男，博士，高级工程师，主要从事航空难加工材料切削加工表面完整性与抗疲劳制造研究。E-mail： jinqichao@chd.edu.cn

Received date: 2024-07-30

  Online published: 2024-09-23

Supported by

the China Postdoctoral Science Foundation(2024M762450)

Fold

Abstract

In order to reveal the formation mechanism of saw tooth-shaped chips in cast & wrought high-temperature alloy GH4198 and predict chip morphology through theoretical models, orthogonal cutting experiments were conducted. Based on the slip line field model, the geometric shape of the chips was predicted, and the influence of cutting parameters on chip formation was analyzed. A three-stage formation model of saw tooth-shaped chips considering the tool edge radius was proposed, and a two-dimension orthogonal cutting thermo-mechanical coupled finite element model was established, with its rationality being verified through experiments. By analyzing the variations of stress, equivalent plastic strain and temperature during the chip formation obtained from simulations, the formation mechanism of saw tooth-shaped chips was investigated. The results show that the shear angle increases with the increase in cutting speed and feed rate, while the chip thickness decreases with the increase in cutting speed. At the cutting speeds of 10, 20 and 30 m/min, the relative errors of the predicted chip thickness are respectively 4.20%, 12.34% and 24.73%, the maximum chip thickness compression ratios are respectively 3.19, 2.78 and 2.26, and the chip serration degrees are respectively 0.20, 0.36 and 0.58. At a cutting speed of 30 m/min, obvious cracks appear in the chips, and the saw teeth exhibit an overall inclined shape. At the feed rates of 0.05, 0.10 and 0.15 mm/r, the relative errors of the predicted minimum chip thickness are respectively 17.66%, 8.66% and 5.07%, the maximum chip thickness compression ratios are respectively 2.82, 2.78 and 2.61, and the chip serration degrees are respectively 0.12, 0.36 and 0.42. The slip line field model effectively predicts the variation of chip thickness with cutting parameters. With the increase in cutting speed and feed rate, the chip thickness compression ratio shows a decreasing trend, while the serration degree increases with a gradually slowing trend. Additionally, the influence of the tool edge radius on chip formation was analyzed through finite element simulation, and the effectiveness of the theoretical model for saw tooth-shaped chip formation was verified.

Key words： cast &; wrought high-temperature alloy GH4198; saw tooth-shaped chip; slip line field; finite element analysis; chip forming mechanism

Cite this article

JIN Qichao , LI Jun , WANG Liangliang , TAN Haibing , LI Fulin , FU Rui , MENG Lingchao , GUO Lei . Mechanism of Saw Tooth-Shaped Chip Formation in Cast & Wrought High-Temperature Alloy GH4198[J]. Journal of South China University of Technology(Natural Science), 2025 , 53(5) : 32 -44 . DOI: 10.12141/j.issn.1000-565X.240390

References

1 李福林，谭海兵，孟令超，等 ．新型铸&锻GH4198合金组织特征及偏析行为［J］．稀有金属，2020，44（8）：807-815．
  LI Fulin， TAN Haibing， MENG Lingchao，et al ．Microstructural characteristics and segregation behavior of a newly developed cast & wrought superalloy GH4198［J］．Chinese Journal of Rare Metals，2020，44（8）：807-815．
2 谷月峰，崔传勇，袁勇，等 ．一种高性能航空涡轮盘用铸锻合金的研究进展［J］．金属学报，2015，51（10）：1191-1206．
  GU Yuefeng， CUI Chuanyong， YUAN Yong，et al ．Research progress in a high performance cast & wrought superalloy for turbine disc applications［J］．Acta Metall Sinica，2015，51（10）：1191-1206．
3 LIU C， WAN M， ZHANG W，et al ．Chip formation mechanism of Inconel 718：a review of models and approaches［J］．Chinese Journal of Mechanical Engineering，2021，34（1）：1-16．
4 LIU D， NI C， WANG Y，et al ．Review of serrated chip characteristics and formation mechanism from conventional to additively manufactured titanium alloys［J］．Journal of Alloys and Compounds，2024，970：172573．
5 VYAS A， SHAW M C ．Mechanics of saw-tooth chip formation in metal cutting［J］．1999，121（2）：163-172．
6 史红艳，赵先锋，姜雪婷 ．滑移线场理论在正交切削过程中的研究现状［J］．华南理工大学学报（自然科学版），2019，47（1）：14-31．
  SHI Hongyan， ZHAO Xianfeng， JIANG Xueting ．Current research on the application of slip line field theory in the orthogonal cutting process［J］．Journal of South China University of Technology （Natural Science Edition），2019，47（1）：14-31．
7 CHEN X， TANG J， DING H，et al ．A new geometric model of serrated chip formation in high-speed machining［J］．Journal of Manufacturing Processes，2021，62：632-645．
8 PANG L， HOSSEINI A， HUSSEIN H M，et al ．Application of a new thick zone model to the cutting mechanics during end-milling［J］．International Journal of Mechanical Sciences，2015，96：91-100．
9 FANG N ．Slip-line modeling of machining with a rounded-edge tool—Part I：new model and theory［J］．Journal of the Mechanics and Physics of Solids，2003，51（4）：715-742．
10 UYSAL A， JAWAHIR I S ．Analysis of slip-line model for serrated chip formation in orthogonal machining of AISI 304 stainless steel under various cooling/lubricating conditions［J］．Journal of Manufacturing Processes，2021，67：447-460．
11 王敏杰，王阳，魏兆成，等 ．切削过程绝热剪切带的滑移线场研究［J］．机械工程学报，2022，58（7）：284-294．
  WANG Minjie， WANG Yang， WEI Zhaocheng，et al ．Slip line field of adiabatic shear band in cutting process［J］．Journal of Mechanical Engineering，2022，58（7）：284-294．
12 CHEN X， TANG J， Ding H，et al ．A new geometric model of serrated chip formation in high-speed machining［J］．Journal of Manufacturing Processes，2021，62：632-645．
13 LI B， ZHANG S， ZHANG Q，et al ．Simulated and experimental analysis on serrated chip formation for hard milling process［J］．Journal of Manufacturing Processes，2019，44：337-348．
14 JOMAA W， MACHRI O， LEVESQUE J，et al ．Finite element simulation and analysis of serrated chip formation during high-speed machining of AA7075-T651 alloy［J］．Journal of Manufacturing Processes，2017，26：446-458．
15 WANG B， LIU Z ．Investigations on the chip formation mechanism and shear localization sensitivity of high-speed machining Ti6Al4V［J］．The International Journal of Advanced Manufacturing Technology，2014，75（5/6/7/8）：1065-1076．
16 付秀丽，艾兴，刘战强，等 ．高速切削加工航空铝合金7050-T7451剪切角模型研究［J］．中国机械工程，2007，18（2）：220-224．
  FU Xiuli， AI Xing， LIU Zhanqiang，et al ．Study on shear angle model of aluminum alloy 7050-T7451 in high speed machining［J］．China Mechanical Engineering，2007，18（2）：220-224．
17 HILL R ．On the limits set by plastic yielding to the intensity of singularities of stress［J］．Journal of the Mechanics and Physics of Solids，1954，2（4）：278-285．
18 刘龙飞，胡少华，卢立伟 ．切削速度对AZ31镁合金高速切削切屑形成的影响［J］．稀有金属，2016，40（7）：654-659．
  LIU Longfei， HU Shaohua， LU Liwei ．Sawtooth chip of AZ31 magnesium alloy under high-speed cutting and different cutting velocities［J］．Chinese Journal of Rare Metals，2016，40（7）：654-659．
19 XIONG Y， WANG W， JIANG R，et al ．Mechanisms and FEM simulation of chip formation in orthogonal cutting in-situ TiB2/7050Al MMC［J］．Materials，2018，11（4）：606/1-19．
20 王兵 ．高速切削材料变形及断裂行为对切屑形成的影响机理研究［D］．济南：山东大学，2016．
21 ZHEN-BIN H， KOMANDURI R ．On a thermomechanical model of shear instability in machining［J］．CIRP Annals，1995，44（1）：69-73．
22 殷继花，林有希，孟鑫鑫，等 ．航空铝合金7075-T651高速铣削锯齿形切屑的形成机理研究［J］．表面技术，2019，48（5）：275-285．
  YIN Ji-hua， LIN You-xi， MENG Xin-xin，et al ．Formation mechanism of sawtooth chip in high speed milling of aeronautical aluminum alloy 7075-T651［J］．Surface Technology，2019，48（5）：275-285．
23 杨奇彪 ．高速切削锯齿形切屑的形成机理及表征［D］．济南：山东大学，2012．
24 谷丽瑶，王敏杰，孙传俊 ．高速切削过程绝热剪切局部化断裂的特性试验［J］．机械工程学报，2014，50（15）：166-171．
  GU Liyao， WANG Minjie， SUN Chuanjun ．Experimental study on characteristics of adiabatic shear loca-lization fracture in high speed machining［J］．Journal of Mechanical Engineering，2014，50（15）：166-171．
25 ZHU X， SHI J， LIU Y，et al ．Study on formation mechanism of serrated chip of Ti-6Al-4V titanium alloy based on shear slip theory［J］．The International Journal of Advanced Manufacturing Technology，2022，122（3/4）：1353-1365．
Options
Outlines

/

〈 〉