Study on tool wear for efficient grooving blisk with disc milling cutter

Tool wear has an important influence on machining quality, cost, cutting force and heat. Grooving blisk with disc milling cutter is 3–4 times more efficient than plunge milling and side milling, but the tool wear is serious because of the large milling force and high milling temperature during the machining process. In the study, the damage and wear morphology of the tool was observed by focused ion/double beam system; the wear mechanism was studied by energy spectrum analysis; the tool life curve was drawn by the increase of flank wear. The experimental results show that the main wear and damage morphologies of disc milling cutter are chip sticking to the tool, chip accumulation, edge collapse, peeling, crack, plastic deformation and boundary wear; the main wear mechanism are abrasive wear, adhesive wear, oxidation wear and diffusion wear; the wear rate of the left blade is the fastest, followed by the right blade, and the wear rate of the middle blade is the slowest. These results can provide guidance for iimproving tool life, optimizing tool and mproving machining processes.