Tool wear analysis of nickel-based superalloy with torus cutter in longitudinal ultrasonic-assisted milling

Nickel-based superalloys are crucial in aerospace applications, but they are challenging to machine due to their high cutting forces and severe tool wear. Conventional machining techniques typically lead to rapid tool degradation and suboptimal surface quality. This study explores the effects of longitudinal ultrasonic-assisted milling (UAM) on tool wear during machining of GH4169 using a torus milling cutter. The results show that UAM prolongs tool life, which is 11.6% higher than that of conventional milling (CM). Compared to UAM, CM is prone to material adhesion and coating delamination, resulting in a built-up layer. UAM generates a more uniform and regular peak-and-valley texture, representing a 39.74% reduction in surface roughness Sa compared to CM. These findings suggest that UAM enhances machining performance by reducing tool wear and improving surface quality, providing a promising approach for machining high-performance alloys.