Nickel-based superalloy is widely employed in aircraft engines and the hot end components of various types of gas turbines with its high strength, strong corrosion resistance and excellent thermal fatigue properties and thermal stability. However, nickel-based superalloy is one of the extremely difficult-to-cut materials. During the machining process, the interaction between the tool and the workpiece causes the severe plastic deformation in the local area of workpiece, and the intense friction at the tool–workpiece interface. The resulting cutting heat coupled with the serious work hardening leads to a series of flaws, such as excessive tool wear, frequent tool change, short tool life, low productivity, and large amount of power consumption etc., in which the excessive tool wear has become one of the main bottlenecks that constraints the machinability of nickel-based superalloys and its wide range of applications. In this article, attention is mainly focused on the tool wear characteristics in the machining of nickel-based superalloys, and the state of the art in the fields of failure mechanism, monitoring and prediction, and control of tool wear are reviewed. The survey of existing works has revealed several gaps in the aspects of tool self-organizing process based on the non-equilibrium thermodynamics, tool wear considering the tool nose radius, thermal diffusion layer in coated tools, tool life prediction based on the thermal–mechanical coupling, and industrial application of tool wear online monitoring devices. The review aims at providing an insight into the tool wear characteristics in the machining of nickel-based superalloys and shows the great potential for further investigations and innovation in the field of tool wear.

Tool wear characteristics in machining of nickel-based superalloys

Uncertainties and dynamic problems of bolted joints and other fasteners

Analytical prediction of cutting tool wear

Cloud-enabled prognosis for manufacturing

Estimation of tool wear in orthogonal cutting using the finite element analysis

Analytical Prediction of Three Dimensional Cutting Process—Part 1: Basic Cutting Model and Energy Approach

The loss energy of a jointed cantibeam may be derived from a microscopic slip and a normal pressure on the interfaces. It is however very difficult to calculate theoretically the energy dissipation between the joint surfaces, because a characteristic of the micro-slip on the interfaces has not been fully clarified yet.In this study the mechanism of the energy dissipation and also the ways of theoretically calculating the damping ratio of the jointed cantibeam have been investigated by considering experimental results of the characteristic of static micro-slip between the jointed surfaces.From the results it is clarified that the damping ratio of the jointed cantibeam can be well calculated by using the equations proposed in this paper, and how the characteristic of micro-slip influences the behaviours of the damping ratio.

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Theoretical Analysis for a Damping Ratio of a Jointed Cantibeam

The heavy machine tools are often made of welded steel and at the same time jointed beam or a damping joint is often used. However the behaviour of the damping capacity of higher mode of vibration of the jointed beam has not been yet fully clarified. In this paper the relationships between the frequency and the damping capacity or the slip ratio and between the damping capacity and the mode of vibration have been experimentally studied by the use of an improved band-width method with two kinds of jointed cantilever beams which are connected with a single bolt and several bolts respectively.

A Study on Damping Capacity of a Jointed Cantilever Beam : 1st Report; Experimental Results

In this paper, the parametric instability in chuck work process is investigated. And an analytical criterion of stability is given, and experimental confirmation is carried out. The vibration of this type is considered to have a significant influence on machinability. However, the applicable isolation of this vibration has not been done. The results obtained are as follows: (1) The parametric vibration is generated by the directional orientation in the stiffness of chucked workpiece. (2) The theoretical analysis for predicting the conditions of parametric instability could be verified by good agreement with the result of cutting test. (3) In the chuck work process, the parametric vibration is amplified with mingling regenerative chatter by the condition of low and fluctuating stiffness.

A Study on Parametric Vibration in Chuck Work

The large-sized machine tools are often made of welded steel and to increase their damping capacity a jointed beam or a damping joint is often used. The behaviour of the damping capacity relating to the first, second and third modes of vibration of the jointed beam had experimentally been studied in the previous report, however, the method for the theoretical calculation of damping capacity of it has not been established yet. In this paper, the relationships between the slip ratio and the damping capacity have been theoretically investigated considering the first and second modes of vibration of the jointed cantilever beams used in the previous study. Through comparison between the experimental values obtained from the previous study and the theoretical values, it has been confirmed that the damping capacity of a jointed cantilever beam can be well estimated by using a method proposed here.

Masami Masuko

Papers

Analytical Prediction of Three Dimensional Cutting Process—Part 1: Basic Cutting Model and Energy Approach

Theoretical Analysis for a Damping Ratio of a Jointed Cantibeam

A Study on Damping Capacity of a Jointed Cantilever Beam : 1st Report; Experimental Results

A Study on Parametric Vibration in Chuck Work

A Study on Damping Capacity of a Jointed Cantilever Beam : 2nd Report, Comparison between Theoretical and Experimental Values