Wear Behavior of PVD and CVD Coated Carbide Tools when Face Milling Inconel 718

The Inconel 718 superalloy is one of the most-used nickel based superalloys in the aerospace industry due to its superior mechanical properties, for instance, high thermal and chemical resistance, and high strength at elevated temperatures. However, the work hardening tendency, low thermal conductivity and high hardness of this superalloy cause early tool wear, leading to the material to be called as a hard-to-cut material. Therefore, deposition of a wear resistant hard coating on carbide cutting tools has a critical importance for longer tool life in milling operations of the Inconel 718 superalloy. In this study, carbide cutting tools were coated with multilayer nanocomposite TiAlSiN/TiSiN/TiAlN coating using the magnetron sputtering technique, and wear behavior of the coated tool was investigated during face milling of the Inconel 718 superalloy under dry conditions. Abrasive and adhesive wear mechanisms were founded as main failure mechanisms. The nanocomposite TiAlSiN/TiSiN/TiAlN coated carbide cutting tool gave better wear resistance, and thus it provided 1.7 times longer tool life and a smoother surface (Ra<0.18 μm) on the Inconel 718 material than the uncoated one.

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Performance comparison of coated carbide tool under different cooling/lubrication environments during face milling of Inconel-625 and Stainless Steel 304

World Journal of Engineering ◽

10.1108/wje-06-2018-0194 ◽

2019 ◽

Vol 16 (2) ◽

pp. 287-295 ◽

Cited By ~ 1

Author(s):

Pragat Singh ◽

J.S. Dureja ◽

Harwinder Singh ◽

Manpreet S. Bhatti

Keyword(s):

Tool Wear ◽

Wear Behavior ◽

Face Milling ◽

Cutting Fluid ◽

Inconel 625 ◽

Machining Performance ◽

Content Type ◽

Stainless Steel 304 ◽

Coated Carbide ◽

Ss 304

PurposeThis study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys).Design/methodology/approachMachining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy.FindingsThe results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life.Research limitations/implicationsInconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions.Originality/valueThe literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly machining.

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A comparison between silicon nitride-based ceramic and coated carbide tools in the face milling of irregular surfaces

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2007.12.035 ◽

2008 ◽

Vol 206 (1-3) ◽

pp. 294-304 ◽

Cited By ~ 12

Author(s):

Anselmo Eduardo Diniz ◽

Jorge Antonio Giles Ferrer

Keyword(s):

Silicon Nitride ◽

Face Milling ◽

Irregular Surfaces ◽

The Face ◽

Coated Carbide ◽

Coated Carbide Tools

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Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.497.94 ◽

2012 ◽

Vol 497 ◽

pp. 94-98

Author(s):

Yang Qiao ◽

Xiu Li Fu ◽

Xue Feng Yang

Keyword(s):

Cutting Force ◽

Feed Rate ◽

Failure Mechanisms ◽

Cutting Temperature ◽

Cutting Speed ◽

Cutting Parameters ◽

Face Milling ◽

Nickel Based Superalloy ◽

Coated Carbide ◽

Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

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Tool Wear Behavior in Turning Inconel 718 with Coated Inserts

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.499.348 ◽

2012 ◽

Vol 499 ◽

pp. 348-352 ◽

Cited By ~ 1

Author(s):

Xiao Li Zhu ◽

Song Zhang ◽

X.L. Xu ◽

H.G. Lv

Keyword(s):

Tool Wear ◽

Inconel 718 ◽

Flank Wear ◽

Wear Behavior ◽

Cutting Tools ◽

Three Dimensional ◽

Cutting Condition ◽

Tool Holder ◽

Final Failure ◽

Coated Carbide

In the present study, an experimental investigation has been carried out in an attempt to monitor tool wear progress in turning Inconel 718 with coated carbide inserts under the wet cutting condition. First, each experimental test was conducted with a new cutting edge and the turning process was stopped at a certain interval of time. Secondly, the indexable insert was removed from the tool holder and the flank wear of the insert was measured using a three-dimensional digital microscopy (VHX-600E); and then the insert was clamped into the tool holder for the next turning experiment. The final failure of tool wear surfaces were examined under a scanning electron microscope (SEM) equipped with an energy dispersive X-ray spectrometer (EDS). It is indicated that significant flank wear was the predominant failure mode, and the abrasive, adhesive and oxidation wear were the most dominant wear mechanisms which directly control the deterioration and final failure of the cutting tools.

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