Modeling and comprehensive mechanism analysis of torus milling cutter wear in multi-axis milling of Ni-based superalloy using the active cutting edge segment change technique

Abstract

Tool wear is a significant challenge in the milling of difficult-to-cut materials such as Ni-based superalloys, as it directly impacts the machining process and surface integrity. In multi-axis torus milling, the complex and varying cutting conditions of cutter-workpiece engagement make predicting wear particularly difficult. This paper proposes models for predicting the life and flank wear of a torus milling cutter equipped with round cutting inserts in a multi-axis milling process. A novel technique for changing the active segment of the cutting edge, specifically designed for torus milling cutters, was used. The cutter-workpiece engagement (CWE) zone was determined and equal width cutting belts were determined on the torus surface. Analysis of wear mechanisms revealed the uneven distribution of flank wear. Based on cutting tests under defined CWE and high-speed machining conditions, predictive models for tool life and flank wear were developed for each active cutting edge segment. These models were calibrated using multi-axis milling experiments on the Inconel718 superalloy. Results demonstrate that the predictive models achieve high accuracy, with average percentage errors below 15 % for tool life and 13 % for flank wear. The models enable precise predictions of torus milling cutter life and flank wear in multi-axis milling of Inconel718 while utilizing the active cutting edge segment change technique. Analysis of wear mechanisms indicated that abrasive and adhesive wear dominates, and flaking and notching wear was also observed.