Performance and Surface Integrity of High-speed Milling of GH4169 with α/β-SiAlON Ceramic Tools

doi:10.3969/j.issn.1004-132X.2026.10.023

Abstract

Abstract:

A type of replaceable α/β-SiAlON ceramic cutting tool with chip-breaking grooves was fabricated by microwave sintering technology. The cutting performance， failure mechanism and surface integrity of the complex-edge-shaped SiAlON ceramic cutting tools during high-speed dry cutting of nickel-based superalloy GH4169 were systematically investigated. The results showed that the service life of the microwave-sintered complex-edge-shaped α/β-SiAlON ceramic cutting tools increased initially and then decreased with increasing cutting speed， while the cutting depth had no significant effect on tool life. The replaceable complex-edge-shaped α/β-SiAlON ceramic cutting tools are more suitable for high-speed and deep-cutting rough processing. The optimal cutting parameters are a cutting speed of 800 m/min， a cutting depth of 1.5 mm， and a feed rate of 0.12 mm per tooth. Under different cutting parameters， bond wear is the main cause of failure of the SiAlON ceramic cutting tools. The surface roughness increased with the increase of cutting speed， and the average surface hardening degree increased from 177 % to 221% when the cutting speed ranged from 600 to 1000 m/min. The variation in surface hardening depth was not obvious with increasing cutting speed and cutting depth， ranging from 240 to 300 μm.

Key words: ceramic tool, SiAlON ceramic, microwave sintering, cutting performance, GH4169 superalloy

摘要：

利用微波烧结技术制备了可转位带槽形α/β-SiAlON陶瓷刀具，系统研究了微波烧结的复杂刃形SiAlON陶瓷刀具高速干切削镍基高温合金GH4169的切削性能、失效机理和加工表面完整性。研究结果表明：微波烧结的复杂刃形α/β-SiAlON陶瓷刀具寿命随铣削速度先增长后缩短，铣削深度对刀具寿命影响不明显，可转位复杂刃形α/β-SiAlON陶瓷刀具更适合高速大切深的粗加工，最优切削参数为铣削速度800 m/min、铣削深度1.5 mm、每齿进给量0.12 mm；在不同切削参数下，黏结磨损是造成SiAlON陶瓷刀具失效的主要原因；加工表面粗糙度随着铣削速度的提高而增大；加工表面硬化程度随着铣削速度的提高（600~1000 m/min）由177%增大至221%，随铣削深度的变化较小，介于180%~190%；硬化深度随着铣削速度和铣削深度的增大变化均不明显，介于240~300 μm。

关键词: 陶瓷刀具, SiAlON陶瓷, 微波烧结, 切削性能, GH4169高温合金

CLC Number:

TG711

WANG Xiaoqin, YIN Zengbin, TANG Haiquan, HONG Dongbo, YUAN Juntang. Performance and Surface Integrity of High-speed Milling of GH4169 with α/β-SiAlON Ceramic Tools[J]. China Mechanical Engineering, 2026, 37(10): 2603-2609.

王晓沁, 殷增斌, 唐海权, 洪东波, 袁军堂. α/β-SiAlON陶瓷刀具高速铣削GH4169性能与表面完整性[J]. 中国机械工程, 2026, 37(10): 2603-2609.

Figures/Tables 17

Fig.1 Cutting test diagram and SiAlON ceramic cutting tools

Fig.2 The influence of cutting parameters on the cutting force of SiAlON ceramic cutting tools during face milling of the high-temperature alloy GH4169

Fig.3 The macroscopic morphology of the chips under different milling depth and SEM microscopic morphology of the shear surfaces and free surfaces

Fig.4 The macroscopic morphology of the chips under different milling speed and SEM microscopic morphology of the shear surfaces and free surfaces

Fig.5 Tool life of complex-edge α/β-SiAlON ceramic cutting tools under different milling depth

Fig.6 Wear diagrams of complex-shaped α/β-SiAlON ceramic cutting tools after machining at different milling depths

Fig.7 SEM morphologies of complex-profiled α/β-SiAlON ceramic inserts under different milling depths

Fig.8 Life curves of complex-edge α/β-SiAlON ceramic cutting tools under different milling speeds

Fig.9 Wear diagrams of complex-shaped α/β-SiAlON ceramic cutting tools after machining at different milling speeds

Fig.10 SEM morphologies of complex-profiled α/β- SiAlON ceramic inserts under different milling speeds

Fig.11 Three-dimensional surface topography under different working conditions

Fig.12 Surface roughness vs. milling depth

Fig.13 Surface roughness vs. milling speed

Fig.14 SEM morphologies of machined surfaces under different working conditions

Fig.15 Influence of milling speed and milling depth on the degree of surface hardening

Fig.16 Test results of surface hardening of workpieces at different milling depths

Fig.17 Test results of surface hardening of workpieces at different milling speeds

References 14

[1]	de BARTOLOMEIS A， NEWMAN S T， JAWAHIR I S， et al. Future Research Directions in the Machining of Inconel 718［J］. Journal of Materials Processing Technology， 2021， 297： 117260.
[2]	YIN Zengbin， HAO Xiaohua， PENG Haohui， et al. A New β-Sialon Ceramic Tool Prepared by Microwave Sintering and Its Cutting Performance in High-speed Dry Machining Inconel718［J］. The International Journal of Advanced Manufacturing Technology， 2022， 118（9/10）： 3105-3117.
[3]	GUO Fuzhou， YIN Zengbin， HONG Dongbo， et al. Cutting Performance of a New Spark Plasma Sintered SiAlON Ceramic Tool for High-speed Milling of Inconel 718［J］. The International Journal of Advanced Manufacturing Technology， 2022， 119（11/12）： 7327-7338.
[4]	PARENTI P， PUGLIELLI F， GOLETTI M， et al. An Experimental Investigation on Inconel 718 Interrupted Cutting with Ceramic Solid End Mills［J］. The International Journal of Advanced Manufacturing Technology， 2021， 117（7）： 2173-2184.
[5]	MING W， HUANG X， JI M， et al. Analysis of Cutting Responses of Sialon Ceramic Tools in High-speed Milling of FGH96 Superalloys［J］. Ceramics International， 2021， 47（1）： 149-156.
[6]	LI Y， ZOU B， SHI Z， et al. Wear Patterns and Mechanisms of Sialon Ceramic End-milling Tool during High Speed Machining of Nickel-based Superalloy［J］. Ceramics International， 2021， 47（4）： 5690-5698.
[7]	FERNÁNDEZ-LUCIO P， PEREIRA NETO O， GÓMEZ-ESCUDERO G， et al. Roughing Milling with Ceramic Tools in Comparison with Sintered Carbide on Nickel-based Alloys［J］. Coatings， 2021， 11（6）： 734.
[8]	MA Z， XU X， HUANG X， et al. Cutting Performance and Tool Wear of SiAlON and TiC-whisker-reinforced Si₃N₄ Ceramic Tools in Side Milling Inconel 718［J］. Ceramics International， 2022， 48（3）： 3096-3108.
[9]	OGHBAEI M， MIRZAEE O. Microwave Versus Conventional Sintering： a Review of Fundamentals， Advantages and Applications［J］. Journal of Alloys and Compounds， 2010， 494（1/2）： 175-189.
[10]	THAKUR A， GANGOPADHYAY S. State-of-the-art in Surface Integrity in Machining of Nickel-based Super Alloys［J］. International Journal of Machine Tools and Manufacture， 2016， 100： 25-54.
[11]	BITTERLICH B， BITSCH S， FRIEDERICH K. SiAlON Based Ceramic Cutting Tools［J］. Journal of the European Ceramic Society， 2008， 28（5）： 989-994.
[12]	殷增斌，朱智勇，王子祥，等. 复杂刃形陶瓷刀具微波烧结技术研究［J］. 中国机械工程， 2022， 33（8）： 899-907.
	YIN Zengbin， ZHU Zhiyong， WANG Zixiang， et al. Study on Microwave Sintering Technology of Complex-shaped Ceramic Tools［J］. China Mechanical Engineering， 2022， 33（8）： 899-907.
[13]	洪东波，殷增斌，陈为友，等. 微波烧结复杂刃形SiAlON陶瓷刀具铣削GH4169高温合金性能研究［J］. 中国机械工程， 2023， 34（7）： 770-779.
	HONG Dongbo， YIN Zengbin， CHEN Weiyou， et al. Cutting Performance of Microwave-sintered Complex-shaped SiAlON Ceramic Cutting Tools in Milling GH4169 Superalloys［J］. China Mechanical Engineering， 2023， 34（7）： 770-779.
[14]	MOLAIEKIYA F， STOLF P， PAIVA J M， et al. Influence of Process Parameters on the Cutting Performance of SiAlON Ceramic Tools during High-speed Dry Face Milling of Hardened Inconel 718［J］. The International Journal of Advanced Manufacturing Technology， 2019， 105（1）： 1083-1098.

[1]	NIU Qiulin, ZHU Chenyi, WU Binghui, ZHANG Shengfeng, GUO Tao, GAO Jingyi. Research Progresses on Synergistic Technology of Micro-textured and Minimum Quantity Lubrication on Tool Surfaces [J]. China Mechanical Engineering, 2026, 37(4): 885-899.
[2]	YU Changrui, LIU Liangbao, ZHOU Jinggang, ZHANG Han, HUANG Dong, ZHANG Ning, LI Xun. Optimization of Roller Burnishing Parameters for Concave Circular-arc Surfaces of Turbine Disk Mortise Grooves [J]. China Mechanical Engineering, 2026, 37(1): 60-65.
[3]	XU Weiwei1, ZHANG Zuoxuan1, ZHU Songqing1, YIN Zengbin2. Experimental Optimization of Microwave Sintering Parameters for Si₃N₄-based Ceramic Materials [J]. China Mechanical Engineering, 2025, 36(03): 435-443.
[4]	ZHOU Houming, CHEN Haoyue, LI Shengui. Preparation and Mechanics Properties of Al2O3/ZrO2 Ceramic Tool Materials Based on Gradient Structure [J]. China Mechanical Engineering, 2023, 34(10): 1199-1207.
[5]	HONG Dongbo, YIN Zengbin, CHEN Weiyou, ZHENG Yitong, YUAN Juntang. Cutting Performance of Microwave-sintered Complex-shaped SiAlON Ceramic Cutting Tools in Milling GH4169 Superalloys [J]. China Mechanical Engineering, 2023, 34(07): 770-779，788.
[6]	LI Xiang, ZHENG Guangming, YAN Pei, SUN Zuomin, CHENG Xiang, LIU Huanbao. Cutting Performance of Coated Tools and Machined Surface Integrity in Superalloy Clean Cutting [J]. China Mechanical Engineering, 2023, 34(04): 454-463.
[7]	ZHANG Shuo, ZOU Ping, FANG Rui, ZHOU Liang. Study on Elliptical Ultrasonic Assisted Machining Performance of Micro Texture Turning Tools [J]. China Mechanical Engineering, 2023, 34(03): 287-291，299.
[8]	ZHANG Yan, HUANG Chuanzhen, LIU Hanlian. Sintering and Mechanics Properties of C3N4 Based Ceramic Tool Materials [J]. China Mechanical Engineering, 2023, 34(03): 352-358，368.
[9]	WU Zhenyu, ZHENG Guangming, YAN Pei, YANG Xianhai, ZHAO Guangxi, LI Xuewei. Effects of Surface Treatment on Surface Integrity and Cutting Performance of TiAlSiN Coated Cutting Tools [J]. China Mechanical Engineering, 2023, 34(01): 75-83.
[10]	YU Liang, ZHENG Guangming, YANG Xianhai, CHENG Xiang, CHANG Kaishuo, LI Xuewei. Effects of Cryogenic Treatment on Cutting Performance of PCBN Tools [J]. China Mechanical Engineering, 2022, 33(20): 2450-2458.
[11]	ZHANG Shuai, CHEN Zhaoqiang, XIAO Guangchun, YI Mingdong, ZHANG Jingjie, ZHOU Tingting, XU Chonghai. Study on Crack Repair Performance of Si3N4/TiC/ZrSi2 Ceramic Tool Materials [J]. China Mechanical Engineering, 2022, 33(19): 2288-2297.
[12]	GUAN Jiju, GAO Chao, XU Zhengya, DING Yunpeng, LI TeXU Xuefeng. Study on Turning Performance of GCr15 Steels with Nanofluids Prepared by Composites of MWCNTs and Oleic Acid [J]. China Mechanical Engineering, 2022, 33(18): 2205-2214，2226.
[13]	FAN Qingbo, YANG Fan, GUAN Xiaoyan, LI Hao, FAN Xiaoqiang, ZHU Minhao. Association between Wear Resistance of TiVN Coatings and Their Cutting Performance [J]. China Mechanical Engineering, 2022, 33(12): 1493-1503.
[14]	YIN Zengbin, ZHU Zhiyong, WANG Zixiang, YUAN Juntang. Study on Microwave Sintering Technology of Complex-shaped Ceramic Tools [J]. China Mechanical Engineering, 2022, 33(08): 899-907.
[15]	YI Mingdong, WANG Jianping, LI Chuanhao, XU Chonghai, . Cutting Characteristics of Tools under Dual Lubrication Conditions [J]. China Mechanical Engineering, 2022, 33(05): 615-622.