Numerical Simulation of Cutting Performance of Coated Tools for Nickel-Based Superalloys

During the machining of nickel-based superalloys using coated tools, a significant amount of cutting heat is generated. This study employs ABAQUS finite element analysis software to establish two-dimensional orthogonal cutting simulation models for three types of coated tools: single-layer AlTiN, double-layer AlTiN/AlCrN, and AlCrN/AlTiN. The research focuses on simulating the cutting temperature and cutting stress of carbide tools with these three different coating types and thicknesses when machining nickel-based superalloy GH4169. The simulation results indicate that the double-layer AlCrN/AlTiN-coated tool exhibits lower maximum cutting temperature and cutting stress on the tool rake face and tool substrate during the cutting process. Compared to the other two coated tools, the cutting temperature and cutting stress on the rake face are reduced by up to 13.2% and 13.3%, respectively. When the AlCrN/AlTiN coating thickness is 2.5 μm with a ratio of 1.5:1, the maximum cutting temperature and cutting stress are minimized. During the cutting process with coated tools, the cutting speed, coating type, and coating thickness significantly influence the maximum cutting temperature and cutting stress. Therefore, investigating the effects of cutting speed, coating type, and coating thickness on carbide-coated tools can reduce tool wear, extend tool life, and thereby improve machining efficiency.