On the Anisotropic Milling Machinability of DD407 Single Crystal Nickel-Based Superalloy

Abstract

The DD407 single crystal Ni-based superalloy with a face-centered cubic structure exhibits strong anisotropic characteristics. In order to reveal the material chip formation mechanism and the impact effect of crystal orientations on the materials’ milling machinability, a combination of experimental observations and theoretical analysis were applied in this study. Considering the resolved shear stress and slip system theories, a fundamental theoretical explanation of the milling force and surface quality along different crystal directions on the (001) crystal plane of the DD407 single crystal Ni-based superalloy was proposed based on a previously constructed anisotropic milling model. Our work in this research verifies that [110] crystal direction on the (001) crystal plane of the DD407 single crystal Ni-based superalloy is the most optimal feeding direction during milling, taking into account surface roughness and morphology, slot bottom plastic deformation, work hardening, and chip edge burr feature.

Experimental study on waterjet guided laser cutting of nickel-based single crystal superalloy

“…; special machining, such as electrical discharge machining (EDM), electrolytic machining, laser machining, etc. Traditional mechanical machining [1,2] method, the process is simple, but the tool manufacturing is difficult and requires high performance such as stiffness and strength of the tool, which generates a lot of heat during the machining process and can easily lead to problems such as tool wear and machining hardening thus affecting the machining quality. Special machining, which is a processing method that mainly uses electrical, thermal, optical, electrochemical and other energy to achieve the removal of materials, has a wide range of processing and good processing quality.…”