CO2 cryogenic milling of Inconel 718: cutting forces and tool wear

This paper reports the results of an experimental study of the tool wear and cutting forces in turning of Inconel 718 with coated carbide inserts. Inconel 718 is a difficult-to-cut nickel-based super-alloy commonly used in aerospace industry. The effects of cutting speed, feed rate and cutting tool geometry on tool wear have been widely analyzed in literature. Turning operations on complex components such as aircraft engines casings require the insert replacement at the end of each geometric feature manufacturing, independently from the actual tool wear level. For this reason, it is important to preserve tool integrity mainly in the most critical phase of operation (i.e., when the tool engages the workpiece). In fact, if the tool is damaged in this stage the quality of the whole operation is compromised. The attention has been focused on engage cutting conditions because the phenomenon that appears in this critical step plays a wide influence on tool integrity and, consequently, on the quality of the operation. For this purpose a nickel-based super alloy ring-workpiece, (Inconel 718), has been machined in lubricated cutting conditions by using a CNC lathe with carbide coated tools. Two variables have been investigated in this study: the Depth Of Cut (DOC) and the approaching Engage angle (En). In the studied working conditions Speed (S), Feed-rate (F) and removed volume (Vrim) were kept constant. Both tool wear and cutting forces evolution during cutting have been analyzed.

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The flank wear prediction in micro-milling Inconel 718

Industrial Lubrication and Tribology ◽

10.1108/ilt-01-2018-0031 ◽

2018 ◽

Vol 70 (8) ◽

pp. 1374-1380 ◽

Cited By ~ 2

Author(s):

Xiaohong Lu ◽

FuRui Wang ◽

Zhenyuan Jia ◽

Steven Y. Liang

Keyword(s):

Finite Element ◽

Tool Wear ◽

Cutting Forces ◽

Inconel 718 ◽

Flank Wear ◽

Milling Process ◽

Micro Milling ◽

Wear Prediction ◽

Content Type ◽

Micro Tool

Purpose Cutting tool wear is known to affect tool life, surface quality, cutting forces and production time. Micro-milling of difficult-to-cut materials like Inconel 718 leads to significant flank wear on the cutting tool. To ensure the respect of final part specifications and to study cutting forces and tool catastrophic failure, flank wear (VB) has to be controlled. This paper aims to achieve flank wear prediction during micro-milling process, which fills the void of the commercial finite element software. Design/methodology/approach Based on tool geometry structure and DEFORM finite element simulation, flank wear of the micro tool during micro-milling process is obtained. Finally, experiments of micro-milling Inconel 718 validate the accuracy of the proposed method for predicting flank wear of the micro tool during micro-milling Inconel 718. Findings A new prediction method for flank wear of the micro tool during micro-milling Inconel 718 based on the assumption that the wear volume can be assumed as a cone-shaped body is proposed. Compared with the existing experiment techniques for predicting tool wear during micro-milling process, the proposed method is simple to operate and is cost-effective. The existing finite element investigations on micro tool wear prediction mainly focus on micro tool axial wear depth, which affects size accuracy of machined workpiece seriously. Originality/value The research can provide significant knowledge on the usage of finite element method in predicting tool wear condition during micro-milling process. In addition, the method presented in this paper can provide support for studying the effect of tool flank wear on cutting forces during micro-milling process.

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Tool wear and cutting forces when machining inconel 718 under cryogenic conditions: Liquid nitrogen and carbon dioxide

10.1063/1.5112610 ◽

2019 ◽

Cited By ~ 2

Author(s):

S. Chaabani ◽

I. Rodriguez ◽

M. Cuesta ◽

Y. Ayed ◽

P. J. Arrazola ◽

...

Keyword(s):

Carbon Dioxide ◽

Tool Wear ◽

Liquid Nitrogen ◽

Cutting Forces ◽

Inconel 718 ◽

Cryogenic Conditions

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Experimental investigation into tool wear, cutting forces, and resulting surface finish during dry and flood coolant slot milling of Inconel 718

Procedia Manufacturing ◽

10.1016/j.promfg.2021.06.026 ◽

2021 ◽

Vol 53 ◽

pp. 236-245

Author(s):

M. Gueli ◽

J. Ma ◽

N. Cococcetta ◽

D. Pearl ◽

M.P. Jahan

Keyword(s):

Experimental Investigation ◽

Tool Wear ◽

Surface Finish ◽

Cutting Forces ◽

Inconel 718 ◽

Slot Milling

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Residual stresses and cutting forces in cryogenic milling of Inconel 718

Procedia CIRP ◽

10.1016/j.procir.2018.08.289 ◽

2018 ◽

Vol 77 ◽

pp. 211-214 ◽

Cited By ~ 2

Author(s):

Gleiton de Paula Oliveira ◽

Maria Cindra Fonseca ◽

Anna Carla Araujo

Keyword(s):

Residual Stresses ◽

Cutting Forces ◽

Inconel 718 ◽

Cryogenic Milling

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Cutting Forces during Inconel 718 Orthogonal Turn-Milling

Materials ◽

10.3390/ma14206152 ◽

2021 ◽

Vol 14 (20) ◽

pp. 6152

Author(s):

Agata Felusiak-Czyryca ◽

Marek Madajewski ◽

Paweł Twardowski ◽

Martyna Wiciak-Pikuła

Keyword(s):

Tool Wear ◽

Cutting Force ◽

Cutting Forces ◽

Inconel 718 ◽

Material Removal ◽

Harsh Environments ◽

Ability To Work ◽

Inconel 718 Alloy ◽

Turn Milling

Inconel 718 is a material often used in the aerospace and marine industries due to its properties and ability to work in harsh environments. However, its machining is difficult, and therefore methods are sought to facilitate this process. One of such methods is turn-milling. This paper presents the forces during orthogonal turn-milling of the Inconel 718 alloy. In this machining, both the side and the end edge are involved in the material removal, which causes the tool to be more loaded. The forces during turn-milling can be up to 50% higher than in the case of milling, which causes damage to the tool. Tool wear during machining has a significant impact on the values of the cutting force proportional coefficients. In the case of the tested material, it is important to take it into account when creating cutting force models.

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Cryogenic Milling: Study of the Effect of CO2 Cooling on Tool Wear When Machining Inconel 718, Grade EA1N Steel and Gamma TiAl

Lubricants ◽

10.3390/lubricants7010010 ◽

2019 ◽

Vol 7 (1) ◽

pp. 10 ◽

Cited By ~ 3

Author(s):

David Fernández ◽

Alejandro Sandá ◽

Ion Bengoetxea

Keyword(s):

Tool Wear ◽

Tool Life ◽

Inconel 718 ◽

New Technology ◽

Cutting Tools ◽

Advanced Materials ◽

High Temperature Strength ◽

Cryogenic Fluids ◽

Cryogenic Milling ◽

Steel Grades

The need for machining advanced materials has increased exponentially in recent years. Ni-based alloys, Ti-based alloys or some steel grades are commonly used in transport, energy generation or biomedicine industries due to their excellent properties that combine hardness, high temperature strength and corrosion resistance. These desirable properties make such alloys extremely difficult to machine, inducing a quick cutting tool wear that must be overcome. In the last decade, cryogenic machining has emerged in order to improve the machining of these materials. By means of cryogenic fluids such as cutting coolants, significant improvements in the life of cutting tools are obtained. However, most studies on this new technology are focused on turning processes, because of the difficulty of introducing cryogenic fluids through a rotary tool in processes such as drilling and milling. In this study, a cryogenic milling system integrated within the tool holder is used for milling Gamma TiAl, Inconel 718 and grade EA1N steel using carbon dioxide as a coolant. This system has been compared with the traditional cooling method (emulsion) in terms of tool life to check if it is possible to improve the machining operation in terms of efficiency by supplying the cryogenic coolant directly to the cutting zone. The results show that by replacing traditional pollutant cooling fluids with other more ecologically-friendly alternatives, it is possible to improve tool life by 100% and 175% in the cases of Gamma TiAl and grade EA1N steel, respectively, when using the new delivery system for the coolant.

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Performance analysis of cryogenically treated plus tempered carbide inserts in turning of Inconel 718 using cryogenic minimum quantity lubrication cooling technique

Proceedings of the Institution of Mechanical Engineers Part J Journal of Engineering Tribology ◽

10.1177/1350650119845744 ◽

2019 ◽

Vol 233 (12) ◽

pp. 1810-1819 ◽

Cited By ~ 4

Author(s):

Venkat Pradeep Allu ◽

D Linga Raju ◽

S Ramakrishna

Keyword(s):

Tool Wear ◽

Cutting Forces ◽

Inconel 718 ◽

Minimum Quantity Lubrication ◽

Chip Morphology ◽

Cryogenic Cooling ◽

Superior Performance ◽

Minimum Quantity ◽

Carbide Inserts ◽

Cryogenic Minimum Quantity Lubrication

The present study deals with performance investigation of cryogenically treated plus tempered carbide inserts during machining of Inconel 718. A novel cooling approach of combined minimum quantity lubrication with cryogenic coolant, cryogenic minimum quantity lubrication is examined to improve the machinability of Inconel 718 and compared with dry, wet, minimum quantity lubrication, and cryogenic cooling conditions. Tool wear, cutting forces, and chip morphology were analyzed to evaluate the effect of cooling under different conditions. The results revealed that minimum quantity lubrication and cryogenic conditions exhibited superior performance than wet and dry conditions. However, severe tool fracture and cutting forces were observed in cryogenic machining which is an outcome of hardened surface of nickel alloy due to cryogenic fluid. Cryogenic minimum quantity lubrication was understood to be the best machining condition generating least cutting force and tool wear. Furthermore, examining chip morphology under scanning electron microscopy revealed that cryogenic minimum quantity lubrication performed stable machining.

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Optimization of machining parameters during micro-milling of Ti6Al4V titanium alloy and Inconel 718 materials using Taguchi method

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

10.1177/0954405415572662 ◽

2016 ◽

Vol 231 (2) ◽

pp. 228-242 ◽

Cited By ~ 34

Author(s):

Emel Kuram ◽

Babur Ozcelik

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

Tool Wear ◽

Wear Surface ◽

Cutting Forces ◽

Inconel 718 ◽

Regression Models ◽

Micro Milling ◽

Depth Of Cut ◽

Ti6al4v Titanium Alloy

This study focused on the optimization of micro-milling parameters for two extensively used aerospace materials (titanium and nickel-based superalloy). The experiments were planned using Taguchi experimental design method, and the influences of spindle speed, feed rate and depth of cut on machining outputs, namely, tool wear, surface roughness and cutting forces, were determined. Tool wear, surface roughness and cutting forces measured in micro-milling of Ti6Al4V titanium alloy and Inconel 718 workpiece materials were optimized by employing Taguchi’s signal-to-noise ratio. The percentage contribution of micro-milling parameters, namely, spindle speed, feed rate and depth of cut, on tool wear, surface roughness and cutting forces was indicated by analysis of variance. The regression models identifying the relationship between the input variables and the output responses were also fitted using experimental data to predict output responses without conducting the experiments. Efficiency of regression models was determined using correlation coefficients, and the predicted values were compared with experimental results. From results, it was concluded that the established regression models could be employed for predicting tool wear, surface roughness and cutting forces in micro-milling of Ti6Al4V titanium alloy and Inconel 718 workpiece materials.

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