Optimization and Experimental Verification of Low Stress Cutting Scheme for GH4065A Superalloy under Multi-parameter Collaborative Control

HE Chunshuang; WU Aijiang; XU Yan; LU Hengyu; LIU Huiru; HU Yuxin; LIU Junbo

doi:10.3969/j.issn.1674-6457.2025.12.007

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (12) : 62-72. DOI: 10.3969/j.issn.1674-6457.2025.12.007

Advanced Aerospace Manufacturing Technology

Optimization and Experimental Verification of Low Stress Cutting Scheme for GH4065A Superalloy under Multi-parameter Collaborative Control

HE Chunshuang¹, WU Aijiang¹, XU Yan¹, LU Hengyu², LIU Huiru², HU Yuxin², LIU Junbo^2,*

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Abstract

In the machining process of GH4065A superalloy turbine discs, improper design of the cutting tool structure and cutting parameters often leads to problems such as low machining accuracy of the turbine disc and excessive cutting stress during the cutting process. The work aims to solve these problems through further research on the structure of the cutting tool and the cutting parameters. Focusing on the process optimization problem in the machining of GH4065A superalloy turbine disc tenon grooves, and through a combination of finite element simulation and experiment, the influence of machining speed (v_c), tooth lift (a), and tool rake angle (B) on material removal rate (MRR), cutting force (F_z, F_y), cutting temperature (T), tool wear, and surface roughness was systematically studied. The research results showed that MMR significantly improved with the increase of tooth lift and cutting speed, but high MRR conditions (such as v_c=2 m/min, a=0.04 mm) were accompanied by high temperature (242 ℃) and cutting force fluctuations, while a medium parameter combination (v_c=2 m/min, a=0.02 mm) could achieve a balance between efficiency and stability (F_z=16.7 kN, F_y=5.43 kN, T=57.5 ℃). The optimal surface roughness (Ra=1.804 μm) occurred in the combination of high cutting speed and medium tooth lift, while low speed or extreme parameters led to roughness deterioration (2.398-2.617 μm). This study is based on multi-objective optimization and proposes a process strategy of “high-speed medium tooth lift (v_c=2 m/min, a=0.02 mm)+moderate rake angle (15°-18°)”, supplemented by cooling control, to provide a theoretical basis for efficient, low stress, and high-precision machining of aircraft engine turbine disc tenon grooves.

Key words

GH4065A superalloy / broaching / material removal rate (MRR) / cutting force / tool wear / surface roughness

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HE Chunshuang, WU Aijiang, XU Yan, LU Hengyu, LIU Huiru, HU Yuxin, LIU Junbo. Optimization and Experimental Verification of Low Stress Cutting Scheme for GH4065A Superalloy under Multi-parameter Collaborative Control[J]. Journal of Netshape Forming Engineering. 2025, 17(12): 62-72 https://doi.org/10.3969/j.issn.1674-6457.2025.12.007

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