scholarly journals An experimental investigation on Inconel 718 interrupted cutting with ceramic solid end mills

2021 ◽  
Author(s):  
Paolo Parenti ◽  
Francesco Puglielli ◽  
Massimo Goletti ◽  
Massimiliano Annoni ◽  
Michele Monno
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Surface Integrity ◽  
Wear Mechanisms ◽  
Inconel 718 ◽  
Turbine Blades ◽  
Cutting Speed ◽  
Material Surface ◽  
End Mills ◽  
Signal Monitoring

AbstractSolid ceramic end mills for machining heat resistant super alloys (HRSA) have the potential to generate higher material removal rates, up to one order of magnitude, with respect to standard carbide tools. The machining operations in aerospace industry, where large removals are required to obtain tiny and slender parts like turbine blades, is a cost-intensive task that can benefit of the adoption of ceramic solid end mills. However, these tools show a quite limited tool life, especially when used with interrupted tool engagement strategies. Moreover, they might induce heat-related problems in the workpiece material surface integrity. This paper investigates the cutting and the tool wear during milling Inconel 718 with solid ø12 mm cutting end tool made by SiAlON. The wear mechanisms are studied together with their effects on process signals as cutting forces and power, measured via external and CNC integrated sensors. The carried experimental campaign allowed to find out that tool clogging and edge chipping were the primary cutting phenomena leading the tool wear. Cutting strategy (downmilling or upmilling) produced different results in terms of tool wear sensitivity and process outputs whereas upmilling configuration showed the best results in terms of cutting signals stability and surface integrity. At the same time, cutting speed was found to increase the cutting power more in upmilling than downmilling cutting. The analysis of the forces and power demonstrated that the typical tool wear mechanisms can be traced by signal monitoring due to their high impact on cutting processes. This fact shows the good potential of signal monitoring for a better tool life evaluation.

scholarly journals Machining of Titanium Metal Matrix Composites: Progress Overview

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 5011
Author(s):  
Cécile Escaich ◽  
Zhongde Shi ◽  
Luc Baron ◽  
Marek Balazinski
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Metal Matrix ◽  
Dust Emission ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Titanium Metal ◽  
Machining Processes ◽  
Tool Wear Mechanisms

The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).

Experimental Analysis of Wear Mechanism and Tool Life in Dry Drilling of Al2024

2012 ◽  
Vol 566 ◽  
pp. 217-221 ◽  
Author(s):  
Ali Davoudinejad ◽  
Sina Alizadeh Ashrafi ◽  
Raja Ishak Raja Hamzah ◽  
Abdolkarim Niazi
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
High Speed ◽  
Thrust Force ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Dry Machining ◽  
Hole Quality ◽  
High Cutting Speed

Aluminum alloy is widely used in industry and various researches has been done on machiability of this material mainly due to its low weight and other superior properties. Dry machining is still interesting topic to reduce the cost of manufacturing and environmental contaminations. In present study dry machining of Al 2024 investigated on tool life, tool wear mechanisms, hole quality, thrust force and torque. Different types of high speed steel (HSS) tools utilized at constant feed rate of 0.04 mm/rev and cutting speeds within the range of 28 and 94 m/min. Experimental results revealed that HSCo drills, performed better than HSS drills in terms of tool life and hole quality. The main wear mechanisms which analyzed by scanning electron microscope found abrasive and adhesion wear on flank face, besides, BUE observed at chisel and cutting edges. However tool wear and BUE formation found more significant at high cutting speed. In terms of thrust force, two facet HSCo tools, recorded higher thrust force than four facet HSS drills.

The Effects of TiAlN and TiN Coating during End Milling of INCONEL 718

2014 ◽  
Vol 564 ◽  
pp. 566-571
Author(s):  
K. Kamdani ◽  
Sulaiman Hasan ◽  
Mohd Amri Lajis
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Speed ◽  
Extreme Condition ◽  
Carbide Tool ◽  
Coated Carbide Tool ◽  
Coated Carbide

Inconel 718 is a registered trademark of Special Metals Corporation that refers to a family of austenitic nickel-chromium-based super alloys. This material usually being used or operate in high temperature and extreme condition like aerospace industry, turbocharger rotors and seals. This research presents an experimental study of the cutting force variation, surface roughness, tool life and tool wear in end milling Inconel 718. The experimental results showed that flank wear was the predominant failure mode affecting tool life for TiAlN and TiN coated carbide tool. TiAlN is the better coated tool than TiN because it produce better surface finish and resultant force. Feed rate is one of the parameter that effecting results in this experiment. The higher feed rate will shorten the life of the tool. Although for the cutting condition, the situation is quite different where the proper cutting speed will maintain the tool life and tool wear for cutting tool. The overall study shows that TiAlN coated carbide tool with cutting speed 100 m/min, depth of cut 0.5 mm and feed rate 0.1 mm/tooth is the optimum parameter in this experiment.

scholarly journals High-Pressure Cooling in Finishing Turning of Haynes 282 Using Carbide Tools: Haynes 282 and Inconel 718 Comparison

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 1916
Author(s):  
Antonio Díaz-Álvarez ◽  
José Díaz-Álvarez ◽  
José Luis Cantero ◽  
Mª Henar Miguélez
Keyword(s):  
High Pressure ◽  
Comparative Analysis ◽  
Tool Wear ◽  
Tool Life ◽  
Inconel 718 ◽  
High Pressures ◽  
Cutting Speed ◽  
Heat Removal ◽  
Cutting Fluids ◽  
Coated Carbide

Despite the interest of industry in nickel-based superalloys and its main features (high temperatures resistance, hardness, low thermal conductivity, among others), even today they are still materials that are difficult to cut. Cutting tools withstand both high pressures and temperatures highly localized at the cutting area because of the elevated work hardening of the alloy and the problems for the cutting fluid to access the region, with the consequent strong tool wear. The use of cutting fluids at high pressures improves coolant access and heat removal. This paper analyzed the machining of Haynes 282 alloy by means of coated carbide tools under high-pressure cutting fluids at finishing conditions. Tests were developed at different cutting speeds and feeds quantifying the machining forces, surface roughness, tool wear, and tool life. Values of 45.9 min and Ra between 2 µm and 1 µm were obtained in this study for tool life and roughness, respectively, for the combination of cutting speed 50 m/min and feed 0.1 mm/rev. Likewise, a comparative analysis is included with the results obtained in previous works developed by the authors relating to the finishing turning of Haynes 282 and Inconel 718 under conventional pressure cooling. The comparative analysis with Inconel 718 is included in the study due to its importance within the nickel base superalloys being widely used in industry and widely analyzed in scientific literature.

Tool wear and surface integrity of inconel 718 in dry and cryogenic coolant at high cutting speed

Wear ◽  
2017 ◽  
Vol 376-377 ◽  
pp. 125-133 ◽  
Author(s):  
A.H. Musfirah ◽  
J.A. Ghani ◽  
C.H. Che Haron
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Cutting Speed ◽  
High Cutting Speed

The effects of cutting speed on tool wear and tool life when machining Inconel 718 with ceramic tools

2007 ◽  
Vol 28 (9) ◽  
pp. 2518-2522 ◽  
Author(s):  
A. Altin ◽  
M. Nalbant ◽  
A. Taskesen
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Ceramic Tools

scholarly journals Study of the Effects of Initial Cutting Conditions and Transition Period on Ultimate Tool Life when Machining Inconel 718

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 592
Author(s):  
Morvarid Memarianpour ◽  
Seyed Ali Niknam ◽  
Sylvain Turenne ◽  
Marek Balazinski
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
Transition Point ◽  
Transition Period ◽  
Initial Conditions ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Reference Condition

Rapid tool wear and limited tool life are major problems when machining Inconel 718, which still need further attention. Amongst the reported strategies, limited studies have been reported on optimizing initial cutting conditions by means of tool life improvement. Therefore, in this work, the tool wear progress and tool life were investigated by varying the initial conditions in the transition period, which was set at four seconds. The transition point was discovered by previous works by the authors. After the transition point, similar cutting conditions were used as the reference condition. The tool wear morphology and size were recorded and analyzed in each condition. It was revealed that applying a lower cutting speed and feed rate in the transition period led to improved tool life as compared to the reference condition. In other words, the use of optimum levels of cutting parameters in the transition period of the cutting process may enhance tool life at higher cutting time. For instance, initial feed rate (0.15 mm/rev) and cutting speed (25 m/min) led to the improvement in the ultimate tool life by about 67% and 50%, respectively. Besides, applying the lower initial cutting speed, i.e., 25 m/min, increased the tool life by about 50% when the insert reached the maximum flank wear (vBmax) of 300 µm in comparison with those at higher initial cutting speeds. This phenomenon may lead to better insight into the effect of the influence of the initial cutting conditions in the transition period on tool life when machining hard-to-cut materials. Moreover, the built-up edge (BUE) was exhibited as the primary wear mode in all cutting conditions.

Tool wear mechanisms of PcBN in machining Inconel 718: Analysis across multiple length scale

CIRP Annals ◽  
2021 ◽  
Author(s):  
Volodymyr Bushlya ◽  
Filip Lenrick ◽  
Axel Bjerke ◽  
Hisham Aboulfadl ◽  
Mattias Thuvander ◽  
...  
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Inconel 718 ◽  
Length Scale ◽  
Tool Wear Mechanisms ◽  
Multiple Length Scale

Effect of tool wear on the surface integrity of Inconel 718 in face milling with cemented carbide tools

Wear ◽  
2021 ◽  
pp. 203752
Author(s):  
A.R.F. Oliveira ◽  
L.R.R. da Silva ◽  
V. Baldin ◽  
M.P.C. Fonseca ◽  
R.B. Silva ◽  
...  
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Face Milling ◽  
Cemented Carbide ◽  
Cemented Carbide Tools
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