Tool wear and surface integrity of inconel 718 in dry and cryogenic coolant at high cutting speed

Wear ◽  
2017 ◽  
Vol 376-377 ◽  
pp. 125-133 ◽  
Author(s):  
A.H. Musfirah ◽  
J.A. Ghani ◽  
C.H. Che Haron
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Cutting Speed ◽  
High Cutting Speed

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.

Effects of Preheating Temperature at Primary Shear Zone in Laser Assisted Milling Process

2019 ◽  
Vol 825 ◽  
pp. 45-50
Author(s):  
Kamonpong Jamkamon ◽  
Keiji Yamada ◽  
Katsuhiko Sekiya ◽  
Ryutaro Tanaka
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Laser Power ◽  
Cutting Speed ◽  
Milling Process ◽  
Machined Surface ◽  
High Cutting Speed ◽  
Preheating Temperature ◽  
Conventional Machining ◽  
Table Speed

In this paper, preheating temperature was investigated for the laser assisted machining (LAM) of Inconel 718 under different conditions for the milling test. The experimental results show that the requirement of laser power for the particularly preheating temperature proportionally increased with the table speed. The resultant cutting force for sufficient shearing work material in LAM was lower than conventional machining (CM) approximately 11, 21 and 28% for the cutting speed of 30, 50 and 75 m/min, respectively. The tool wear in LAM could be improved at relatively high cutting speed of 75 m/min and the hardness of machined surface in LAM was slightly higher than CM.

Effect of tool wear on the surface integrity of Inconel 718 in face milling with cemented carbide tools

Wear ◽  
2021 ◽  
pp. 203752
Author(s):  
A.R.F. Oliveira ◽  
L.R.R. da Silva ◽  
V. Baldin ◽  
M.P.C. Fonseca ◽  
R.B. Silva ◽  
...  
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Face Milling ◽  
Cemented Carbide ◽  
Cemented Carbide Tools

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

Study of a High Performance AFM Probe-Based Microscribing Process

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
Keith Bourne ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
Tool Wear ◽  
High Performance ◽  
Cutting Speed ◽  
Rake Angle ◽  
Motion Platform ◽  
High Cutting Speed ◽  
Working Volume ◽  
Afm Probe ◽  
Tool Motion ◽  
Five Axis

In this paper, a mechanical microscribing process is described that combines AFM probe-based microscribing with a five-axis microscale machine tool motion platform in order to achieve high scribing speeds, a large working volume, and the capability of cutting curvilinear patterns of grooves. An experiment is described that demonstrates groove formation, groove shape, and tool wear when long grooves are formed using multiple tool passes. A second more systematic experiment is described in which short-distance single-pass cutting tests were used to explore the effects of cutting speed, nominal tool load, and AFM probe mounting angle on groove geometry, tool wear, effective rake angle, and chip formation. Lastly, an experiment is described in which a long curvilinear groove is cut. It is shown that the most well-formed grooves were cut and acceptable tool wear was achieved, when using a high cutting speed, high nominal tool load, and low probe mounting angle. The capability of cutting grooves as long at 82 mm but with depths of only a few hundred nanometers, using a single tool pass at cutting speeds as high at 25 mm/min is demonstrated.

scholarly journals Comparison between cryogenic coolants effect on tool wear and surface integrity in finishing turning of Inconel 718

2020 ◽  
Vol 285 ◽  
pp. 116780
Author(s):  
S. Chaabani ◽  
P.J. Arrazola ◽  
Y. Ayed ◽  
A. Madariaga ◽  
A. Tidu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718

Performance Evaluation of PVD and CVD Coated Inserts during End Milling with DRY and MQL Condition

2017 ◽  
Vol 867 ◽  
pp. 165-170
Author(s):  
Isha Srivastava ◽  
Ajay Batish
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Sem Analysis ◽  
Depth Of Cut ◽  
High Cutting Speed ◽  
Cutting Operation ◽  
En 31

The aim of this study were to evaluate the performance of PVD (TiAlN+TiN) and CVD (TiCN+Al2O3+TiN) coated inserts in end milling of EN–31 hardened die steel of 43±1 HRC during dry and MQL (Minimum quantity lubrication) machining. The experiments were conducted at a fixed feed rate, depth of cut and varying cutting speed to measure the effect of cutting speed on cutting force and tool wear of CVD and PVD-coated inserts. The performance of CVD and PVD-coated inserts under dry and MQL condition by measuring the tool wear and cutting force were compared. During cutting operation, it was noticed that PVD inserts provide less cutting force and tool wear as compared to the CVD inserts under both dry as well as the MQL condition because PVD inserts have a thin insert coating and CVD inserts have a thick insert coating, but PVD inserts experience catastrophic failure during cutting operation whereas CVD inserts have a capability for continuous machining under different machining. Tool wear has measured by SEM analysis. The result shows that MQL machining provides the optimum results as compared to the dry condition. MQL machining has the ability to work under high cutting speed. As the cutting speed increases the performance of dry machining was decreased, but in MQL machining, the performance of the inserts was increased with increases of cutting speed. MQL machining generates less cutting force on the cutting zone and reduces the tool wear which further increase the tool life.

Tool Wear of Polycrystalline Cubic Boron Nitride Compact Tools in Cutting Hardened Steel

2012 ◽  
Vol 488-489 ◽  
pp. 724-728 ◽  
Author(s):  
Tadahiro Wada
Keyword(s):  
Particle Size ◽  
Boron Nitride ◽  
Tool Wear ◽  
Tool Life ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Polycrystalline Cubic Boron Nitride ◽  
Cbn Tool ◽  
High Cutting Speed

Using polycrystalline cubic boron nitride compact (cBN) tools, which have different cBN contents and cBN particle sizes, the influences of both the cBN content and the cBN particle size on tool wear in turning of hardened steel at various cutting speeds was experimentally investigated. Three types of cBN tools (a cBN content of 45-55% and 75%, and a cBN particle size of 0.5 μm and 5 μm, respectively) were tested. Furthermore, three kinds of chamfered and honed cutting edges were also used. The main results obtained are as follows: (1) In the case of the cBN tools with the same cBN particle size of 5.0 μm, the tool life of the cBN tool with a cBN content of 75% was longer than that of the cBN tool with a cBN content of 45% at low cutting speed. However, at high cutting speed, the tool life of the cBN tool with a cBN content of 75% was shorter. (2) The tool life of the cBN tool with both a cBN content of 55% and a cBN particle size of 0.5 μm was the longest. (3) The tool wear of cBN tools decreased with a decrease in chamfer width.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

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