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Experimental study on the machining performance of nickel-based superalloy GH4169 milled by AWJ

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Abstract

The experimental study of AWJ milling performance of nickel-based superalloy materials is the basis for the study of milling process parameter optimization. Therefore, this paper focuses on the effect law of process parameters (waterjet pressure, abrasive flow rate, nozzle traverse speed, nozzle tilt angle and step-over distance) on milling performance (milling depth and surface roughness) when milling of nickel-based superalloys via AWJ. The prediction models of milling depth and surface roughness were established using the response surface method. The waterjet pressure is the factor that affects the milling depth and surface roughness the most, while the abrasive flow rate is the factor that affects the milling depth and surface roughness the least. In the interaction term of the milling depth model, the maximum milling depth is obtained at low waterjet pressure when the nozzle tilt angle is between 60° and 80°. While at high waterjet pressure, the maximum milling depth is obtained when the nozzle tilt angle is close to 90°; at any step-over distance, the effect on the milling depth is smaller when the nozzle traverse speed increases above 25 mm/s. In the interaction term of the surface roughness model, when the waterjet pressure is low, there is an optimal nozzle traverse speed to minimize the surface roughness value; at a higher nozzle traverse speed, the minimum surface roughness value occurs at minimum step-over distance. The validation experiment shows that the maximum relative error of the milling depth model is 10.09% and the maximum relative error of the surface roughness model is 12.12%, which proves the validity of the established milling depth model and surface roughness model.

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Funding

This work is supported by the National Natural Science Foundation of China (No.52275446, 51805296, 52105318) and Guangdong Basic and Applied Basic Research Foundation (No.2023A1515030278) and Key Projects of the Joint Fund for Regional Innovation and Development of NSFC (No. U22A20195) and Young Scholars Future Program of Shandong University.

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Authors and Affiliations

  1. Center for Advanced Jet Engineering Technologies (CaJET), Key Laboratory of High-Efficiency and Clean Mechanical Manufacture (Ministry of Education), National Demonstration Center for Experimental Mechanical Engineering Education (Shandong University), School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Weijie Zhang, Dun Liu, Yifei Zhang, Hongtao Zhu, Yue Dai & Junqi Wang

  2. Shenzhen Research Institute of Shandong University, Shenzhen, 518057, China

    Dun Liu

  3. School of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, China

    Chuanzhen Huang

  4. School of Mechanical Engineering, University of Science and Technology Beijing, Beijing, 100083, China

    Shaochuan Feng

Authors
  1. Weijie Zhang
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  2. Dun Liu
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  3. Yifei Zhang
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  4. Hongtao Zhu
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  5. Chuanzhen Huang
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  7. Junqi Wang
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  8. Shaochuan Feng
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Contributions

Weijie Zhang: Methodology, Validation, Writing-original draft. Dun Liu: Funding acquisition, Project administration, Supervision, Writing-Review & Editing. Yifei Zhang: Investigation, Formal analysis; Hongtao Zhu: Investigation, Formal analysis; Chuanzhen Huang: Supervision, Resources; Yue Dai: Experiments, Visualization; Junqi Wang: Software, Experiments. Shaochuan Feng: Validation, Visualization.

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Correspondence to Dun Liu.

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Zhang, W., Liu, D., Zhang, Y. et al. Experimental study on the machining performance of nickel-based superalloy GH4169 milled by AWJ. Int J Adv Manuf Technol 129, 1175–1188 (2023). https://doi.org/10.1007/s00170-023-12327-8

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