Failure mechanisms of graded ceramic tool in ultra high speed dry milling of Inconel 718

2013 ◽  
Vol 14 (6) ◽  
pp. 943-949 ◽  
Author(s):  
Guangming Zheng ◽  
Jun Zhao ◽  
Anhai Li ◽  
Xiaobin Cui ◽  
Yonghui Zhou
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Failure Mechanisms ◽  
Dry Milling ◽  
Ceramic Tool ◽  
Ultra High Speed ◽  
Graded Ceramic Tool

Self-Sharpening Failure Characteristic of a Si3N4 Ceramic Tool in High Speed Cutting of Inconel 718

2016 ◽  
Vol 693 ◽  
pp. 1135-1142 ◽  
Author(s):  
Guang Ming Zheng ◽  
Jun Zhao ◽  
Xiang Cheng ◽  
Min Wang
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Adhesive Wear ◽  
Failure Mechanisms ◽  
Cutting Edge ◽  
Ceramic Tool ◽  
Tool Failure ◽  
High Speed Cutting ◽  
Failure Characteristic ◽  
Failure Evolution

A Si3N4 ceramic tool material with high mechanical properties was fabricated by hot-pressing sintering process. The high speed machining of Inconel 718 tests were carried out with round ceramic inserts. The failure surface and microstructure were analyzed by scanning electron microscopy (SEM) to reveal the ceramic tool failure mechanisms. The results showed that the main failure mechanisms of the Si3N4 ceramic tool were flaking, micro-chipping, abrasive wear and adhesive wear in the turning process. On the other hand, chipping, flaking and adhesive wear were the main failure reasons in the milling process. Meanwhile, some small flaking along the cutting edge and step-shaped flaking on the rake face closed to the cutting edge were found on the failure surfaces, which was a typical self-sharpening failure characteristic of the ceramic tool in the high-speed cutting process. This tool failure evolution characteristic of the ceramic tool can be attributed to its higher flexural strength and fracture toughness, which was beneficial to improve the tool life and was constrained by cutting conditions.

Study on Cutting Performance and Wear Mechanisms of Graded Ceramic Tool

2014 ◽  
Vol 490-491 ◽  
pp. 358-361
Author(s):  
Yan Zheng Li ◽  
Zhong De Shan ◽  
Jun Zhao ◽  
Jing Yun Xiong
Keyword(s):  
Ductile Iron ◽  
Wear Mechanisms ◽  
High Speed ◽  
Nickel Content ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Ceramic Tool ◽  
Dry Cutting ◽  
Short Segment ◽  
Graded Ceramic Tool

In this paper, based on the experiments of high speed dry cutting nickel alloyed ductile iron with different nickel contents by graded ceramic tool, the cutting performance and wear mechanisms of graded ceramic tool were investigated. Results reveal that with the increase of cutting speed and nickel content the wear of graded ceramic tool is increased, wear mechanisms are transformated spalling and cohesive wear from abrasive wear, and chip shapes are turned into long arc segment from short segment.

Ultra High Speed Turning of Inconel 718 with Sialon Ceramic Tools

2010 ◽  
Vol 126-128 ◽  
pp. 653-657 ◽  
Author(s):  
Guang Ming Zheng ◽  
Jun Zhao ◽  
Xin Yu Song ◽  
Cao Qing Yan ◽  
Yue En Li
Keyword(s):  
Wear Mechanisms ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Cutting Condition ◽  
Inconel 718 Alloy ◽  
High Speed Turning ◽  
Sialon Ceramic ◽  
Ultra High Speed

This paper explores the wear mechanisms of a Sialon ceramic tool in ultra high speed turning of Nickel-based alloy Inconel 718. Microstructures of the chips are also investigated. Stereo optical microscope and scanning electron microscope (SEM) are employed to observe worn surfaces of the tool produced by various wear mechanisms and morphological features of chips. In addition, the elemental compositions of wear products are evaluated by energy-dispersive X-ray spectroscopy (EDS). As a result of the study, wear mechanisms identified in the machining tests involve adhesive wear and abrasive wear. At the initial stage of cutting process, crater wear and flank wear are the main wear patterns. At the rapid wear stage, the SEM and EDS results showed that the adhered elements of Inconel 718 alloy on the tool rake face such as Ni, Fe and Cr accelerated the tool wear rate. Meanwhile, it was found that the chip morphology was serrated type under ultra high speed cutting condition, furthermore, the tendency of serration of the chip increased with the increase in cutting speed and feed rate.

A Study of Cutting Forces in High-Speed Dry Milling of Inconel 718

2012 ◽  
Vol 500 ◽  
pp. 105-110 ◽  
Author(s):  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Cutting Forces ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Yield ◽  
Dry Milling ◽  
Machining Processes ◽  
Dry Cutting ◽  
High Tendency ◽  
Coated Carbide

nconel 718 is one of the most commercially important superalloys but with very poor machinability. It has a very high yield stress and a high tendency to adhesion and work-hardening. A recent trend of improving the machining processes of difficult-to-cut materials is to move towards dry cutting operations. This paper presents an experimental study of the cutting forces in high speed dry milling of Inconel 718 using a milling cutter with coated carbide inserts. It is found that the peak cutting forces increase with an increase in chip load in a nonlinear way, but cutting speed does not show a significant influence on the cutting force for the range of cutting speeds tested in this study.

Performance of graded nano-composite ceramic tools in ultra-high-speed milling of Inconel 718

2013 ◽  
Vol 67 (9-12) ◽  
pp. 2799-2810 ◽  
Author(s):  
Guangming Zheng ◽  
Jun Zhao ◽  
Yonghui Zhou ◽  
Anhai Li ◽  
Xiaobin Cui ◽  
...  
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Composite Ceramic ◽  
Nano Composite ◽  
High Speed Milling ◽  
Ceramic Tools ◽  
Ultra High Speed

Performance of Si3N4/(W, Ti)C graded ceramic tool in high-speed turning iron-based superalloys

2018 ◽  
Vol 44 (13) ◽  
pp. 15579-15587 ◽  
Author(s):  
Xianhua Tian ◽  
Jun Zhao ◽  
Xinya Wang ◽  
Haifeng Yang ◽  
Zhongbin Wang
Keyword(s):  
High Speed ◽  
Ceramic Tool ◽  
High Speed Turning ◽  
Graded Ceramic Tool ◽  
Iron Based

Influence of Coolant Application Direction on the Cutting Performance of Ceramic Tool in High-Speed Air-Jet-Assisted Machining of Inconel 718

2017 ◽  
Vol 749 ◽  
pp. 87-93
Author(s):  
Toshiyuki Obikawa ◽  
Masashi Yamaguchi
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Necessary Condition ◽  
Nickel Base Superalloy ◽  
Ceramic Tool ◽  
Air Jet ◽  
Nickel Base ◽  
Base Superalloy

This paper describes the high speed air-jet-assisted machining of nickel-base superalloy with a SiC whisker reinforced alumina insert. This machining method showed already good performance in high speed machining of Inconel 718. In this paper, the influence of the application direction of coolant on the tool wear and tool life was investigated for obtaining much better cutting performance of the ceramic tool. The coolant was applied from the side of flank face with three different directions: two oblique directions from the end and side flank faces and the perpendicular direction to the cutting edges. In contrast, the application direction of the air jet was always perpendicular to the cutting edges. The experimental results showed that the best performance in the air-jet-assisted machining was obtained by applying coolant from the side of side flank at a cutting speed of 420 m/min and from the side of end flank at a cutting speed of 780 m/min. The necessary condition found for the best performance was that the size of notch wear was a little larger than that of flank wear.

Air Jet Assisted Machining of Inconel 718 with Whisker Reinforced Ceramic Tool

2013 ◽  
Vol 554-557 ◽  
pp. 2079-2084 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Kazuhiro Funai
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Chemical Properties ◽  
High Speed Machining ◽  
Ceramic Tool ◽  
Air Jet ◽  
Hot Machining ◽  
Notch Wear

Nickel alloy is widely applied to aero-engines, marine structures, chemical plants, etc. This alloy has superior mechanical and chemical properties, but is one of difficult-to-machine materials because of its superior properties. For this reason, various machining methods, such as cryogenic machining, hot machining, machining using high pressure coolant and rotary machining have been studied for increasing the cutting speed and cutting efficiency of this alloy. Recently, a new lubrication method called air jet assisted (AJA) machining was developed to extend tool life by 20-30% in finish-turning of Inconel 718 and Ti-6Al-4V. In this machining method air jet as well as coolant was applied to the cutting area. In this study, AJA machining was applied to high speed machining of Inconel 718 with a SiC whisker reinforced ceramic tool. The air jet was applied from an air nozzle at the tool flank face. Because the ceramic tool is likely to suffer from severe notch wear, the influence of AJA machining on flank and notch wear of the ceramic tool was investigated experimentally. As a result, it was found that as compared to conventional wet machining, AJA machining increased flank wear but reduced notch wear, which is usually critical to the tool life of the reinforced ceramic tool. The tool wear characteristics peculiar to AJA machining were effective for extending tool life in high speed machining of this alloy.

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