Wear mechanism and experimental study of a tool used for micro-milling single-crystal nickel-based superalloys

To study the wear mechanism of micro-tools that cut superalloy materials, a single-crystal nickel-based superalloy DD98 was micro-milled by a cemented carbide milling tool with a 0.6-mm diameter, and the wear standard for the micro-milling tool was established based on the change in the tool diameter and groove bottom width after wear. Then, the wear mathematical model for the micro-milling tool was established. The wear mechanism and wear form of the micro-milling tool that cut the single-crystal nickel-based superalloy were observed with scanning electron microscopy (SEM). The influence of the element change of the tool and workpiece material during the cutting process and workpiece performance were proposed based on the energy spectroscopy analysis. The relevant mechanism and experimental data have theoretical significance for exploring the cutting mechanism of difficult-to-machine materials.