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Superalloys are widely used in the aerospace field and are a typical difficult-to-cut material. When the PCBN tool is used to cut superalloys, there will be problems such as a large cutting force, a high cutting temperature, and gradual tool wear. High-pressure cooling technology can effectively solve these problems. Therefore, this paper carried out an experimental study of a PCBN tool cutting superalloys under high-pressure cooling and analyzed the influence of high-pressure coolant on the characteristics of the cutting layer. The results show that the main cutting force can be reduced by 19~45% and 11~39% when cutting superalloys under high-pressure cooling compared with dry cutting and atmospheric pressure cutting, respectively, in the range of test parameters. The surface roughness of the machined workpiece is less affected by the high-pressure coolant, but the high-pressure coolant can help reduce the surface residual stress. The high-pressure coolant can effectively improve the chip’s breaking ability. In order to ensure the service life of PCBN tools, when cutting superalloys under high-pressure cooling the coolant pressure should not be too high, and 50 bar is more appropriate. This provides a certain technical basis for the efficient cutting of superalloys under high-pressure cooling conditions.

High temperature and strain will occur in the cutting area during dry milling of contour bevel gears, which causes plastic deformation of the workpiece, resulting in changes in the physical properties of the machined surface’s metamorphic layer, reducing the quality of the workpiece’s machined surface. Therefore, it is necessary to investigate the properties of the metamorphic layer and the work hardening behavior of the machined surfaces of contour bevel gears. The paper first establishes a single-tooth finite element simulation model for a contour bevel gear and extracts the temperature field, strain field and strain rate at different depths from the machined surface. Then, based on the simulation results, the experiment of milling contour bevel gears is carried out, the microscopic properties of the machined metamorphic layer are studied using XRD diffractometer and ultra-deep field microscopy, and the work hardening behavior of the machined metamorphic layer under different cutting parameters is studied. Finally, the influence of the cutting parameters on the thickness of the metamorphic layer of the machined surface is investigated by scanning electron microscopy. The research results can not only improve the surface quality and machinability of the workpiece, but are also significant for increasing the fatigue strength of the workpiece.