Effects of Cutting Speed on Chip Characteristics and Tool Wear Mechanisms During Dry Machining of Inconel 718 Using Uncoated WC Tool

2019 ◽  
Vol 44 (9) ◽  
pp. 7423-7440 ◽  
Author(s):  
Merugu Rakesh ◽  
Saurav Datta
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Dry Machining ◽  
Tool Wear Mechanisms ◽  
On Chip

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

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.).

Comparison of Round Insert's Lifetime when Milling Inconel 718

2013 ◽  
Vol 581 ◽  
pp. 26-31
Author(s):  
Ivan Mrkvica ◽  
Miroslav Janoš
Keyword(s):  
Tool Wear ◽  
Corrosive Medium ◽  
Wear Mechanisms ◽  
Inconel 718 ◽  
Experimental Tests ◽  
Cutting Conditions ◽  
Tool Wear Mechanisms ◽  
Wear Mode ◽  
Resistive Material ◽  
Cutting Speeds

This article focuses on the analysis of tool wear mechanisms in milling of Inconel 718. Inconel 718 is tough and highly temperature resistive material, which is used due to its excellent properties especially in aggressive corrosive medium. Machining of this alloy is still complicated. The feasibility of four inserts tested for milling of Inconel 718 has been shown in the work. Different cutting speeds and feeds were used. Experimental tests were performed in order to analyze wear patterns evolution. It was found influence of cutting conditions and type if insert in tool wear mode.

scholarly journals Effect of cutting speed on chip formation and wear mechanisms of coated carbide tools when ultra-high-speed face milling titanium alloy Ti-6Al-4V

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771370 ◽  
Author(s):  
Anhai Li ◽  
Jun Zhao ◽  
Guanming Hou
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Wear Mechanisms ◽  
Failure Mechanisms ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Face Milling ◽  
Formation Mechanisms ◽  
Tool Wear Mechanisms ◽  
Cutting Speeds

Chip morphology and its formation mechanisms, cutting force, cutting power, specific cutting energy, tool wear, and tool wear mechanisms at different cutting speeds of 100–3000 m/min during dry face milling of Ti-6Al-4V alloy using physical vapor deposition-(Ti,Al)N-TiN-coated cemented carbide tools were investigated. The cutting speed was linked to the chip formation process and tool failure mechanisms of the coated cemented cutting tools. Results revealed that the machined chips exhibited clear saw-tooth profile and were almost segmented at high cutting speeds, and apparent degree of saw-tooth chip morphology occurred as cutting speed increased. Abrasion in the flank face, the adhered chips on the wear surface, and even melt chips were the most typical wear forms. Complex and synergistic interactions among abrasive wear, coating delamination, adhesive wear, oxidation wear, and thermal mechanical–mechanical impacts were the main wear or failure mechanisms. As the cutting speed was very high (>2000 m/min), discontinuous or fragment chips and even melt chips were produced, but few chips can be collected because the chips easily burned under the extremely high cutting temperature. Large area flaking, extreme abrasion, and serious adhesion dominated the wear patterns, and the tool wear mechanisms were the interaction of thermal wear and mechanical wear or failure under the ultra-high frequency and strong impact thermo-mechanical loads.

An Experimental Study on Rough Ball-End Milling of T10A Steel

2011 ◽  
Vol 188 ◽  
pp. 78-83
Author(s):  
Xin Qiang Zhuang ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Bin Zou ◽  
H.L. Liu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Cutting Speed ◽  
Main Tool ◽  
Depth Of Cut ◽  
Tool Wear Mechanisms ◽  
Radial Depth ◽  
Coated Cemented Carbide

The milling experiments of the annealed T10A steel were carried out in the various cutting conditions using the coated cemented carbide tool. The cutting parameters were designed by the multi-factor orthogonal experiment method, and the effects of cutting speed, feed, axial depth of cut and radial depth of cut on the cutting force and tool wear were investigated. The tool wear mechanisms were also discussed. Adhesion, abrasion, diffusion and oxidation were the main tool wear mechanisms. According to these investigations, the optimizing cutting parameter was recommended.

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.

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.

Sign in / Sign up

Export Citation Format

Share Document