Simulation and experimental study on machining Waspaloy superalloy by micro flat bottom bit

Due to their numerous advantages, nickel-based alloys are widely utilized in turbine and aero-engine blades. The processing of micro holes in these alloys requires employing a micro flat bottom bit, as well as the placement and fixed connections between small parts. On the other hand, the nickel-based alloy Waspaloy is a typical tough material with great flexibility, hardness, corrosion preventive, and other characteristics. Combining theory, simulation, and experiment, the influence of cutting parameters on axial force, tool wear, hole morphology, surface roughness of the hole wall, and chip morphology was analyzed by using the single-factor method to study the machining conditions of the micro drill and workpiece in flat bore micro-hole processing more rationally and accurately. The results show that under the condition of low feed fate and high spindle speed, the axial force is smaller, the service life of micro drill is longer and the machining micro hole accuracy is higher.