The nickel-based superalloy GH4169 is widely used in key structural components such as aircraft engines due to its excellent high-temperature strength and corrosion resistance. However, in traditional cutting processes, the surface layer is prone to forming a metamorphic layer under thermal mechanical coupling, which in turn affects the fatigue life and service reliability of the parts. To achieve accurate prediction of metamorphic layer thickness, this paper constructs a multi physics coupled model considering instantaneous cutting thickness changes, shear angle evolution, and non-uniform stress-strain distribution based on the Cattaneo–Vernotte non-Fourier heat conduction model. The model uses the dynamic recrystallization starting temperature as a criterion to achieve theoretical calculation of the thickness of the metamorphic layer. By conducting dry cutting experiments under different cutting speeds, the prediction accuracy of the model was verified. The results showed that the model can accurately reflect the influence of speed changes on the thickness of the metamorphic layer, and the prediction error is controlled within 5%.
LuXDuJDengQ, et al. Stress rupture properties of GH4169 superalloy. J Mater Res Technol2014; 3(2): 107–113.
2.
ZhouJBushlyaVAvdovicP, et al. Study of surface quality in high speed turning of Inconel 718 with uncoated and coated CBN tools. Int J Adv Manuf Technol2012; 58(1–4): 141–151.
3.
PalmertFAlmrothPGustafssonD, et al. Modelling the crack growth behaviour of a single crystal nickel base superalloy under TMF loading with long dwell times. Int J Fatigue2020; 144(12): 106074.
4.
NiSWangYBLiaoXZ, et al. Strain hardening and softening in a nanocrystalline Ni–Fe alloy induced by severe plastic deformation. Mater Sci Eng A2011; 528(9): 3398–3403.
5.
NiewczasM.Chapter 75. Dislocations and twinning in face centred cubic crystals. In: NabarroFRNHirthJP (eds) Dislocations in solids, Elsevier Science, vol. 13, 2007, pp.263–364.
6.
BabitskyVIMitrofanovAVSilberschmidtVV.Ultrasonically assisted turning of aviation materials: simulations and experimental study. Ultrasonics2004; 42(1–9): 81–86.
7.
ChenDYTsaoCCLinMY, et al. Ultrasonic-assisted on the turning of Inconel 718 by Taguchi method. Adv Mater Res2012; 579: 160–173.
8.
KimGDLohBG.Direct machining of micro patterns on nickel alloy and mold steel by vibration assisted cutting. Int J Precis Eng Manuf2011; 12(4): 583–588.
9.
RenXPLiuZQ.Microstructure refinement and work hardening in a machined surface layer induced by turning Inconel 718 super alloy. Int J Miner Metall Mater2018; 25(8): 937–949.
10.
HaoZPChengGFanYH.Dynamic plastic evolution mechanism in cutting zone of nickel-based superalloy GH4169. J Mater Process Technol2023; 313(1): 117858.
11.
ChangBQYiZXDuanJ, et al. Microstructure evolution characterization of GH4169 superalloy under ultrasonic high-frequency vibration energy. Mater Charact2023; 198: 112717.
12.
LinYCWenDXDengJ, et al. Constitutive models for high-temperature flow behaviors of a Ni-based superalloy. Mater Des2014; 59(9): 115–123.
13.
ChenYXYangYQFengZQ, et al. Grain refinement and texture evolution during high precision machining of a Ni-based superalloy. Philos Mag2017; 97(1): 28–42.
14.
TanRKZhaoXSSunT, et al. Experimental investigation on micro-groove manufacturing of Ti-6Al-4V alloy by using ultrasonic elliptical vibration assisted cutting. Materials2019; 12(19): 3086.
15.
BaiWSunRLLeopoldJ, et al. Microstructural evolution of Ti6Al4V in ultrasonically assisted cutting: numerical modelling and experimental analysis. Ultrasonics2017; 78: 70–82.
16.
HouZBKomanduriR.General solutions for stationary/moving plane heat source problems in manufacturing and tribology. Int J Heat Mass Transf2000; 43(10): 1679–1698.
17.
ZhangYFaghriA.An integral approximate solution of heat transfer in the grinding process. Int J Heat Mass Transf1996; 39(13): 2653–2662.
18.
ParkitnyRWinczekJ.Analytical solution of temporary temperature field in half-infinite body caused by moving tilted volumetric heat source. Int J Heat Mass Transf2013; 60: 469–479.
19.
FoeckererTZaehMFZhangOB.A three-dimensional analytical model to predict the thermo-metallurgical effects within the surface layer during grinding and grind-hardening. Int J Heat Mass Transf2013; 56(1–2): 223–237.
20.
MitrofanovABabitskyVSilberschmidtV.Thermomechanical finite element simulations of ultrasonically assisted turning. Comput Mater Sci2004; 32(3): 463–471.
21.
LiangXLLiuZQRenLF, et al. Analytical model for thermo-mechanical interaction induced residual stress distribution during multi-conditional machining Inconel 718. Mech Syst Signal Process2023; 204: 110835.
22.
KingstedtOLewAPrattM, et al. Investigation of thermomechanical coupling in Inconel 718 at homologous temperatures of 0.2 and 0.5. Metall Mater Trans A2024; 55(9): 3591–3600.
23.
WeiMWuMYXuJM, et al. Influence of flank wear on the microstructure characteristics of the GH4169 metamorphic layer under high-pressure cooling. Materials2023; 16(8): 2944.
24.
MaoCZengTHHuYL, et al. A comparative study on microstructure evolution of metamorphic layers induced by grinding and laser quenching in hardened AISI 52100 steel. Surf Coat Technol2025; 507: 132142.
25.
WangCYLiCYMiaoHH, et al. Analysis of high-speed cutting surface layer formation and oxide layer thickness prediction of titanium alloy (Ti6Al4V). Materials2025; 18(13): 3160.
26.
NielsH.Hall–Petch relation and boundary strengthening. Scr Mater2004; 51(8): 801–806.
27.
LinYChenMZhongJ.Constitutive modeling for elevated temperature flow behavior of 42CrMo steel. Comput Mater Sci2007; 42(3): 470–477.
28.
HuangKLogéR.A review of dynamic recrystallization phenomena in metallic materials. Mater Des2016; 111: 548–574.
29.
LinYChenX.A critical review of experimental results and constitutive descriptions for metals and alloys in hot working. Mater Des2011; 32(4): 1733–1759.
30.
MerchantEM. Mechanics of the metal cutting process. I. Orthogonal cutting and a type 2 chip. J Appl Phys1945; 16(5): 267–275.
31.
FanYHWangTHaoZP, et al. Research on tool wear based on multi-scale simulation in high speed cutting Inconel718. Arch Civ Mech Eng2018; 18(3): 928–940.
32.
OxleyPLBYoungHT. The mechanics of machining: an analytical approach to assessing machinability. Wear1990; 150(1–2): 380–381.
33.
ZaeraRRodríguez-MartínezJARittelD.On the Taylor–Quinney coefficient in dynamically phase transforming materials. Application to 304 stainless steel. Int J Plast2013; 40: 185–201.
34.
TzouDY.A unified field approach for heat conduction from macro- to micro-scales. J Heat Transf1995; 117(1): 8–16.
35.
HerwigHBechertK.Experimental evidence about the controversy concerning Fourier or non-Fourier heat conduction in materials with a nonhomogeneous inner structure. Heat Mass Transf2000; 36(5): 387–392.
36.
van der MerweAJvan RensburgNFJSieberhagenRH.Comparing the dual phase lag, Cattaneo–Vernotte and Fourier heat conduction models using modal analysis. Appl Math Comput2021; 396: 125934.
37.
JiaDSunWXuDS, et al. Dynamic recrystallization behavior of GH4169G alloy during hot compressive deformation. J Mater Sci Technol2019; 35(09): 45–53.
38.
KimCK.An analytical solution to heat conduction with a moving heat source. J Mech Sci Technol2011; 25(4): 895–899.
39.
CarslawHSJaegerJC.Conduction of heat in solids. 2nd ed.Clarendon Press, 1959, pp.510–520.
40.
MusfirahAHGhaniJAHaronCCH. Tool wear and surface integrity of Inconel 718 in dry and cryogenic coolant at high cutting speed. Wear2017; 376–377: 125–133.
