The study on force, surface integrity, tool life and chip on laser assisted machining of inconel 718 using Nd:YAG laser source

In laser-assisted machining (LAM), the laser source is focused on the workpiece as a thermal source and locally increases the workpiece temperature and makes the material soft ahead of the cutting tool so using this method, the machining forces are reduced, which causes improving the surface quality and cutting tool life. Machinability of advanced hard materials is significantly low and conventional methods do not work effectively. Therefore, utilizing an advanced method is inevitable. The product life and performance of complex parts of the leading industry depends on surface integrity. In this work, the surface integrity features including microhardness, grain size and surface roughness (Ra) and also the maximum cutting temperature were investigated experimentally in LAM of Ti-6Al-4V. According to the results, cutting speed has inverse effect on the effectiveness of LAM process because with increasing speed (15 to 63 m/min), temperature decreases (524 °C to 359 °C) and surface roughness increases (0.57 to 0.71 μm). Enhancing depth of cut and feed has direct effect on the process temperature, grain size, microhardness and surface roughness.

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Surface integrity and tool life when turning Inconel 718 using ultra-high pressure and flood coolant systems

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1243/09544054jem936 ◽

2008 ◽

Vol 222 (6) ◽

pp. 653-664 ◽

Cited By ~ 57

Author(s):

A R C Sharman ◽

J I Hughes ◽

K Ridgway

Keyword(s):

High Pressure ◽

Tool Life ◽

Surface Integrity ◽

Inconel 718 ◽

Ultra High Pressure

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

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-021-07148-6 ◽

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.

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