Study on cutting performance and wear mechanism of SiAlON ceramic tools in high-speed face milling of GH4169

Nickel-based superalloys are currently an indispensable core material within aero-engine manufacturing because of their superior high-temperature mechanical attributes, including outstanding toughness and oxidation resistance under extremely extreme temperatures of 800°C. This research intends to uncover the cutting performance and wear mechanism of different types of SiAlON ceramic tools, CS300 and 6160, throughout high-speed face milling of GH4169. Through experimental design, the impact of cutting speed ( v c = 600–1100 m/min) and feed per tooth ( f z = 0.05–0.08 mm/z) on cutting performance were studied, and key parameters such as instantaneous cutting temperature, workpiece surface quality and machine tool cutting power were collected. Combined with SEM and energy EDS analysis, the wear and failure mechanism of SiAlON ceramic tools under high-speed cutting circumstances were systematically revealed. The outcome show that the primary wear modes of the flank of the two SiAlON ceramic tools are notch, microcracks, flaking, adhesive, and diffusion wear. When v c = 900–1100 m/min, the workpiece surface is thermally softened, and the flank wear of the two SiAlON ceramic tools is minimal, indicating that this speed range is suitable for high-speed cutting of GH4169. Further comparison shows that the CS300 tool exhibits less flank wear, better machined surface quality, and lower machine tool energy consumption than the 6160 tool, confirming its superior cutting performance.