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

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

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

2020 ◽  
Vol 9 (4) ◽  
pp. 8459-8468 ◽  
Author(s):  
Octavio Pereira ◽  
Ainhoa Celaya ◽  
Gorka Urbikaín ◽  
Adrián Rodríguez ◽  
Asier Fernández-Valdivielso ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cryogenic Milling

Through-Tool Coolant Drilling of Aluminum/SiC Metal Matrix Composite1

2000 ◽  
Vol 122 (4) ◽  
pp. 384-388 ◽  
Author(s):  
Stuart Barnes ◽  
Ian R. Pashby
Keyword(s):  
Tool Wear ◽  
Beneficial Effect ◽  
Titanium Nitride ◽  
Surface Finish ◽  
Strong Evidence ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Solid Carbide ◽  
Cutting Operation ◽  
Tool Cooling

Through-tool coolant was applied to the drilling of an aluminum/SiC MMC. Titanium nitride coated, solid carbide drills were used to investigate the effect of the coolant application method on the performance of the drilling operation. Holes were produced dry, with conventional coolant and with through-the tool coolant. The results provided strong evidence that the conventional application of coolant was having no beneficial effect on the cutting operation compared to dry drilling. However, through-tool cooling gave a significant improvement in performance in terms of tool wear, cutting forces, surface finish and the height of the burrs produced. [S0094-4289(00)02104-6]

Cutting forces, tool wear and surface finish in high speed diamond machining

2017 ◽  
Vol 49 ◽  
pp. 293-304 ◽  
Author(s):  
Ekkard Brinksmeier ◽  
Werner Preuss ◽  
Oltmann Riemer ◽  
Rüdiger Rentsch
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Forces ◽  
High Speed ◽  
Diamond Machining

Influence of sustainable cutting environments on cutting forces, surface roughness and tool wear in turning of Inconel 718

2018 ◽  
Vol 5 (2) ◽  
pp. 6746-6754 ◽  
Author(s):  
A Mehta ◽  
S. Hemakumar ◽  
A. Patil ◽  
S.P. Khandke ◽  
P. Kuppan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718

Machining Performance of PM Material Containing MnX Additives1

2000 ◽  
Vol 122 (4) ◽  
pp. 379-383 ◽  
Author(s):  
Stuart Barnes ◽  
Michael J. Nash ◽  
Moh. H. Lim
Keyword(s):  
Powder Metallurgy ◽  
Tool Wear ◽  
Surface Finish ◽  
Cutting Forces ◽  
Superior Performance ◽  
Machining Performance ◽  
Turning Operation ◽  
Cutting Speeds

A new free-machining additive, MnX, has been reported to improve the machining performance of ferrous powder metallurgy (PM) materials. This work investigated this claim by comparing the performance of three otherwise identical PM materials containing: no additive, conventional manganese sulphide (MnS) additions and the new MnX additive. A turning operation and cutting speeds of 100–250 m/min were used during which cutting forces, tool wear and surface finish were measured. The MnX material was found to exhibit superior performance. However, this was most noticeable at higher cutting speeds and at the lower cutting speeds, differences in performance were substantially reduced. [S0094-4289(00)02004-1]

New Machining Method for Nickel Based Thermal Sprays

1994 ◽  
Author(s):  
Joel H. Cohen ◽  
James H. Dailey
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Inconel 718 ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Machining Parameters ◽  
Air Plasma ◽  
Thermal Sprays ◽  
Part Surface ◽  
Rapid Tool

The routine overhaul and repair of gas turbine components requires dimensional restoration of many components. This process is usually accomplished by using various thermal sprays to build up the worn part surface and then machining or grinding the thermal sprays to correct part tolerances and dimensions. These surfaces usually contain numerous holes that generate heavily interrupted surfaces to be machined. The combination of interrupted cuts and a very wear resistant thermal spray causes rapid tool wear on conventional carbide cutting tools. This rapid tool wear also produces poor surface finish, part taper, chipping around the hole edges, and increased tool pressure that could result in lifting or peeling of the sprayed material from the parent metal. This paper summarizes the results of machining nickel based thermal sprays with polycrystalline cubic boron nitride (PCBN) cutting tools. The tests have shown a minimum 2–5x improvement in surface finish, dimensional control, part taper and up to 10x increase in productivity. The PCBN tools also generated lower cutting forces resulting in reduced stress and higher bond strengths in the part. This paper presents the data collected and the recommended machining parameters developed under controlled conditions for machining air plasma sprayed Metco 443, Metco 450, Inconel 718, two wire arc applied TAFA 75B, TAFA 73MXC, and high velocity oxygen fuel applied Inconel 718.

Tool Engage Investigation in Nickel Superalloy Turning Operations

2012 ◽  
Vol 504-506 ◽  
pp. 1305-1310 ◽  
Author(s):  
Antonio del Prete ◽  
Antonio Alberto de Vitis ◽  
Luigino Filice ◽  
Serafino Caruso ◽  
Domenico Umbrello
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Turning Operations ◽  
Coated Carbide ◽  
Super Alloy

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.

Tool wear and resulting surface finish during micro slot milling of polycarbonates using uncoated and coated carbide tools

2019 ◽  
Vol 234 (1-2) ◽  
pp. 52-65 ◽  
Author(s):  
Muhammad Pervej Jahan ◽  
Jianfeng Ma ◽  
Craig Hanson ◽  
Greg K Arbuckle
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Feed Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Slot Milling ◽  
Coated Tools ◽  
Tool Coating ◽  
Micro Channels

A growing application of polycarbonates is in the microfluidic disks and DNA detection devices, where surface finish of the micro-channels plays an important role. This study intends to investigate the tool wear and surface finish generated during micro slot milling of polycarbonate using uncoated, TiN-coated, and TiAlN-coated tungsten carbide tools. The effects of tool coating and the machining parameters on the possible reduction of tool wear and improvement of surface finish were investigated. It was found that with careful selection of cutting parameters and tool coating, micro-channels with smoother surface finish, minimum burrs around the edges, and controlled tool wear can be obtained using micro-milling. A combination of medium range of depth of cut and feed rate was found to improve the surface finish in polycarbonates, as well as minimize the tool wear. The TiAlN tool coating was found to only be effective in reducing tool wear without much effect on the machined surface. The adhesion was found to be the most dominating tool wear mechanism in uncoated carbide tool, followed by cutting edge chipping and tool nose’s plastic failure. The adhesion wear was found to be reduced in coated tools, especially in TiAlN-coated tools, although delamination wear started to dominate in the coated tools when higher feed rate and depth of cut were used. Both lower and higher of depths of cut were found to generate higher tool wear and leave traces of tool marks on the machined surface.

The flank wear prediction in micro-milling Inconel 718

2018 ◽  
Vol 70 (8) ◽  
pp. 1374-1380 ◽  
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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