EFFECTS OF MILLING METHODS AND COOLING STRATEGIES ON TOOL WEAR, CHIP MORPHOLOGY AND SURFACE ROUGHNESS IN HIGH SPEED END-MILLING OF INCONEL-718

2019 ◽  
Vol 21 (1/2) ◽  
pp. 1
Author(s):  
Paras Mohan Jasra ◽  
Anthony Chukwujekwu Okafor
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Chip Morphology ◽  
Cooling Strategies

Analysis of Machinability of Inconel 718 in High Speed End Milling with Ceramic Inserts under Room Temperature Conditions

2012 ◽  
Vol 538-541 ◽  
pp. 1351-1355
Author(s):  
A.K.M. Nurul Amin ◽  
Suhaily Mokhtar ◽  
Muammer Din Arif
Keyword(s):  
Surface Roughness ◽  
Silicon Nitride ◽  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Room Temperature ◽  
End Milling ◽  
High Speed Machining ◽  
Temperature Conditions ◽  
Notch Wear

Inconel 718 is used for high-temperature applications in aerospace, nuclear, and automotive industries due to its resistance, at high temperatures, to corrosion, fatigue, creep, oxidation, and deformation. Unfortunately, these same qualities also impair its machinability and researchers have investigated on ways to machine it economically. Some unconventional machining practices such as: Plasma Enhanced and Laser Assisted Machining etc. have been applied. However these practices increase the machining cost. This research investigated the viability of high speed end milling of Inconel 718 using circular Silicon Nitride (ceramic) inserts under room temperature conditions. Tool wear (flank and notch wear), machining vibration amplitude and average surface roughness were evaluated for the feasibility analysis. A vertical CNC mill was used to machine Inconel 718 samples using different combinations of three primary machining parameters: cutting speed, feed, and depth of cut. Vibration data acquisition device and Datalog DasyLab 5.6 software were used to analyze machining vibration. Scanning Electron Microscope (SEM) and surface profilometer were utilized to measure tool (flank and notch) wear and surface roughness, respectively. It was observed that the machining vibrations, in high speed machining, was reasonable (0.045 V on the average). This resulted in acceptable tool wear (averages: flank wear = 0.25 mm, notch wear = 0.45 mm) and semi-finished surface roughness (0.30 µm) measured after every 30 mm length of cut. Thus, room temperature high speed machining of Inconel 718 using circular silicon nitride inserts is a practical option.

Investigation on Chip Morphology and Surface Quality in High-Speed Ball-End Milling of Inconel 718

2010 ◽  
Vol 443 ◽  
pp. 353-358 ◽  
Author(s):  
Harshad A. Sonawane ◽  
Suhas S. Joshi
Keyword(s):  
Surface Quality ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Chip Morphology ◽  
Helix Angle ◽  
Processing Parameters ◽  
Milling Process ◽  
Machining Parameters ◽  
Ball End Milling

The ball end milling process, commonly used for generating complex shapes, involves continuous variation in the uncut chip dimensions, which depends on the cutter geometry and the machining parameters. The proposed analytical model evaluates the undeformed and the deformed chip dimensions including chip length, width and thickness. The undeformed and deformed chip dimensions, is a function of cutter rotation angle, instantaneous cutter radius, helix angle, and other processing parameters. The surface quality, in the form of surface roughness, during high-speed ball end milling of Inconel 718 is also analysed in this paper.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

Effect of Tool Wear on Surface Qualities in Milling of TC4

2016 ◽  
Vol 836-837 ◽  
pp. 132-138 ◽  
Author(s):  
Shu Cai Yang ◽  
Xiao Yang Cui ◽  
Yu Hua Zhang ◽  
Zhi Wei Wang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
End Milling ◽  
Great Influence ◽  
Chip Morphology ◽  
Milling Process ◽  
Serrated Chip ◽  
Quality Surface

Tool wear is easy occurred in titanium alloy milling process which will affect the surface quality. Surface roughness and surface morphology as an important index to describe and evaluate the surface quality has a great influence on service performance. Therefore, the study on the effect of tool wear on surface qualities is important to improve the surface integrity of titanium alloy parts. Cutting radius of ball-end milling cutter is solved to analyze the effect of tool wear on the cutting radius. The tool wear and the surface qualities of TC4 are achieved through wear experiment. And then the influence law of tool wear on surface qualities and chip morphology are analyzed. The results show that surface roughness value decrease firstly and then increases and that chip morphology with flank wear increase from the unit chip to the serrated chip.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Evaluation of Surface Roughness and Tool Wear in High Speed Machining of Inconel 718

2019 ◽  
Vol 943 ◽  
pp. 66-71
Author(s):  
Moola Mohan Reddy ◽  
Viviana Yong Chai Nie
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
High Speed Machining ◽  
Super Alloy

This research work considered the high speed milling operation of Inconel 718 using a 4 flute solid carbide end mill tool without the use of coolant. Inconel 718 is a Nickel based Heat Resistance Super Alloy (HRSA) that is vastly used in the aerospace industries due to its excellent corrosion resistance and good mechanical properties. However, Inconel 718 is considered as a difficult-to-cut super alloy, which poses several problems when machining the material. The aim of this work is to investigate the effect and the influence of cutting parameters (feed rate, spindle speed, and depth of cut) on the quality of the machined surface as well as to evaluate the tool wear after machining. This evaluation of the surface roughness was done using a CNC milling machine at various parameters range for the values of feed rate (50-150 mm/min), spindle speed (2000-4000 RPM), and depth of cut (0.05-0.1 mm). The experiment was designed using Response Surface Analysis Method with Central Composite Design (CCD) to optimize the experimentation. The resulting tool wear and surface roughness after high speed machining were then analysed using ANOVA to determine the cutting parameters which is most affecting the surface roughness.

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