Cutting Forces during Inconel 718 Orthogonal 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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Experimental studies on graphite powder-mixed electro-discharge machining of Inconel 718 super alloys: Comparison with conventional electro-discharge machining

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering ◽

10.1177/0954408918787104 ◽

2018 ◽

Vol 233 (2) ◽

pp. 384-402 ◽

Cited By ~ 8

Author(s):

Santosh Kumar Sahu ◽

Saurav Datta

Keyword(s):

Thermal Conductivity ◽

Residual Stress ◽

Wear Rate ◽

Tool Wear ◽

Inconel 718 ◽

Material Removal ◽

Graphite Powder ◽

Tool Wear Rate ◽

Machined Surface ◽

Electro Discharge Machining

Inconel 718 is a nickel-based super alloy widely applied in aerospace, automotive, and defense industries. Low thermal conductivity, extreme high temperature strength, strong work-hardening tendency make the alloy difficult-to-cut. In contrast to traditional machining, nonconventional route like electro-discharge machining is relatively more advantageous to machine this alloy. However, low thermal conductivity of Inconel 718 restricts electro-discharge machining from performing well. In order to improve the electro-discharge machining performance of Inconel 718, powder-mixed electro-discharge machining was reported in this paper. It was carried out by adding graphite powder to the dielectric media in consideration with varied peak discharge current. The morphology and topographical features of the machined surface including surface roughness, crack density, white layer thickness, metallurgical aspects (phase transformation, crystallite size, microstrain, and dislocation density), material migration, residual stress, microindentation hardness, etc. were studied and compared with that of the conventional electro-discharge machining. Additionally, effects of peak discharge current were discussed on influencing different performance measures of powder-mixed electro-discharge machining. Material removal efficiency and tool wear rate were also examined. Use of graphite powder-mixed electro-discharge machining was found to be better in performance for improved material removal rate, superior surface finish, reduced tool wear rate, and reduced intensity as well as severity of surface cracking. Lesser extent of carbon migration onto the machined surface as observed in powder-mixed electro-discharge machining in turn reduced the formation of hard carbide layers. As compared to the conventional electro-discharge machining, graphite powder-mixed electro-discharge machining exhibited relatively less microhardness and residual stress at the machined surface.

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

Journal of Materials Research and Technology ◽

10.1016/j.jmrt.2020.05.118 ◽

2020 ◽

Vol 9 (4) ◽

pp. 8459-8468 ◽

Cited By ~ 6

Author(s):

Octavio Pereira ◽

Ainhoa Celaya ◽

Gorka Urbikaín ◽

Adrián Rodríguez ◽

Asier Fernández-Valdivielso ◽

...

Keyword(s):

Tool Wear ◽

Cutting Forces ◽

Inconel 718 ◽

Cryogenic Milling

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A cutting forces model for milling Inconel 718 alloy based on a material constitutive law

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406212469167 ◽

2012 ◽

Vol 227 (8) ◽

pp. 1761-1775 ◽

Cited By ~ 9

Author(s):

HZ Li ◽

J Wang

Keyword(s):

Cutting Forces ◽

Inconel 718 ◽

Shear Plane ◽

Material Model ◽

Constitutive Law ◽

Percentage Error ◽

Force Model ◽

Inconel 718 Alloy ◽

Average Percentage ◽

Constitutive Material Model

This article presents a cutting force model for the milling of Inconel 718 whose machinability is considered to be very poor. The Johnson–Cook constitutive material model is used to determine the flow stress of Inconel 718 while the shear angle is determined based on a shear plane model assuming that the total energy on the shear plane plus the energy on the rake face is minimum. The temperature in the machining region is determined by using an iterative process. Finally, the cutting forces on each tooth of the milling cutter are calculated from its chip load considering the oblique cutting effects. The model is then verified by comparing the model predictions with the experimental data under the corresponding conditions, which shows a relatively good agreement with an average percentage error of 10.5% along the feed and normal directions.

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Cutting Force Analysis of on-Machine Fabricated PCD Tool during Glass Micro-Grinding

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.1085 ◽

2011 ◽

Vol 264-265 ◽

pp. 1085-1090 ◽

Cited By ~ 3

Author(s):

Asma Perveen ◽

Muhammad Pervej Jahan ◽

Yoke San Wong ◽

Mustafizur Rahman

Keyword(s):

Cutting Force ◽

Cutting Forces ◽

Material Removal ◽

Depth Of Cut ◽

Machined Surface ◽

Hard Materials ◽

Pcd Tool ◽

Fluidic Devices ◽

Micro Machine ◽

Poly Crystalline Diamond

Brittle and hard materials are problematic to mechanically micro machine due to damage resulting from material removal by brittle fracture, cutting force-induced tool deflection or breakage and tool wear. As a result, the forces arising from the cutting process are important parameter for material removal. This study was undertaken to investigate the effect of cutting conditions on cutting forces and the machined surface during the glass micro grinding using on-machine fabricated (Poly Crystalline Diamond) PCD tool. Experimental results showed that an increase in depth of cut and feed rate can result in increase of cutting forces and surface roughness as well. Among the forces in 3 axes, force along feed direction is found to be larger, which played a major role in material removal. Finally, it is observed that PCD tool exhibits promising behaviour to machine brittle material like BK-7 glass for producing micro molds and micro fluidic devices, since it has better wear resistance, experiences less cutting forces and generates smooth surfaces with Ra value of as low as 12.79 nm.

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Next Generation Insert for Forced Coolant Application in Machining of Inconel 718

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.340 ◽

2016 ◽

Vol 836-837 ◽

pp. 340-347 ◽

Cited By ~ 4

Author(s):

Nageswaran Tamil Alagan ◽

Tomas Beno ◽

Anders Wretland

Keyword(s):

Tool Wear ◽

Surface Area ◽

Inconel 718 ◽

Material Removal ◽

Metal Cutting ◽

Heat Dissipation ◽

Catastrophic Failure ◽

Mass Ratio ◽

Next Generation ◽

Primary Focus

Machining technology has undergone an extensive evolution throughout the last decades in its capability to machine hard-to-cut material. This paper will discuss about the next generation insert with cooling feature coupled with forced coolant in machining Inconel 718. The geometry of the insert was changed in a way which has enlarged the surface area approximately 12% compared to regular insert named as nusselt insert. The idea applied in “nusselt insert” was the relation of increase in surface area to heat dissipation. Forced coolant application has become a way to improve existing metal cutting concepts and improve their current material removal rates without any need for a reengineered machining process.Experiments conducted on the inserts is that the first experiment of its kind in machining technology together with forced coolant and tested in four different inserts. The primary focus of the work was the investigation of the relation between the heat dissipation with an increase in surface area/mass ratio in the cutting interface based on its influence on tool wear. The experimental results showed the nusselt insert have better ability for heat dissipation which has led to significant reduce in tool wear and successfully facing Inconel 718 at vc 105 m/min, f 0.3 mm/rev and ap 1 mm where the regular insert had a catastrophic failure at vc 90 m/min, f 0.1 mm/rev and ap 1 mm. Nusselt insert has shown to increase MRR significantly compared to regular insert.

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Finite Element Simulation of the Cutting Process for Inconel 718 Alloy Using a New Material Constitutive Model

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.693.1046 ◽

2016 ◽

Vol 693 ◽

pp. 1046-1053

Author(s):

Xiang Yu Wang ◽

Chuan Zhen Huang ◽

Jun Wang ◽

Bin Zou ◽

Guo Liang Liu ◽

...

Keyword(s):

Finite Element ◽

Constitutive Model ◽

Finite Element Simulation ◽

Cutting Forces ◽

Inconel 718 ◽

Cutting Process ◽

Inconel 718 Alloy ◽

Cutting Edge Radius ◽

Material Constitutive Model ◽

Element Simulation

Inconel 718 alloy is a typical difficult-to-cut material and widely used in the aerospace industry. Finite element simulation is an efficient method to investigate the cutting process, whereby a work material constitutive model plays an important role. In this paper, finite element simulation of the cutting process for Inconel 718 alloy using a new material constitutive model for high strain rates is presented. The effect of tool cutting edge radius on the cutting forces and temperature is then investigated with a view to facilitate cutting tool design. It is found that as the cutting edge radius increases, the characteristics of tool-work friction and the material removal mechanisms change, resulting in variation in cutting forces and temperature. It is shown that a smaller cutting edge radius is preferred to reduce the cutting forces and cutting temperature.

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EXPERIMENTAL INVESTIGATION OF EFFECT OF CRYO-TREATMENT ON MICROMILLING OF INCONEL 718

Surface Review and Letters ◽

10.1142/s0218625x20500018 ◽

2020 ◽

Vol 27 (11) ◽

pp. 2050001

Author(s):

PADMAJA TRIPATHY ◽

KALIPADA MAITY

Keyword(s):

Tool Wear ◽

Material Removal Rate ◽

Inconel 718 ◽

Material Removal ◽

High Speed ◽

Removal Rate ◽

Cryogenic Treatment ◽

High Speed Steel ◽

End Mill ◽

Micro End Mill

In this paper, the effect of cutting parameters during micromilling on surface finish and material removal rate is presented. Inconel 718 alloy and high-speed steel micro end mill are used as work material and cutting tool, respectively. High-speed steel end mill of 1 mm diameter is subjected to cryogenic treatment. Machining studies are performed on Inconel alloy using untreated and cryogenic treated cutters. The milling tests are conducted at three different values of feed rate, cutting speed and depth of cut. Also, tool wear, microstructure and microhardness of different treated and untreated end mill are investigated and discussed in detail. The results showed that cryogenic treatment significantly improved the tool wear. The surface finish produced on machining the work-piece is better with the cryogenic treated tools than when compared with the untreated tools. The material removal rate is better with the cryogenic treated tools than when compared with the untreated tools. Improvement in tool life was up to 53.16% for Inconel 718 material when machined with cryogenically treated micro end mill.

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Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2020.116809 ◽

2020 ◽

Vol 285 ◽

pp. 116809 ◽

Cited By ~ 4

Author(s):

Bastien Toubhans ◽

Guillaume Fromentin ◽

Fabien Viprey ◽

Habib Karaouni ◽

Théo Dorlin

Keyword(s):

Tool Wear ◽

Cutting Force ◽

Surface Integrity ◽

Inconel 718 ◽

Force Model ◽

Cutting Force Model

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Influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface

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

10.1177/0954405417716495 ◽

2017 ◽

Vol 233 (1) ◽

pp. 18-30 ◽

Cited By ~ 6

Author(s):

Jian-wei Ma ◽

Zhen-yuan Jia ◽

Guang-zhi He ◽

Zhen Liu ◽

Xiao-xuan Zhao ◽

...

Keyword(s):

Tool Wear ◽

Cutting Force ◽

Tool Life ◽

Inconel 718 ◽

High Speed ◽

Cutting Tool ◽

Helix Angle ◽

Curved Surface ◽

Geometrical Parameters ◽

High Speed Milling

High-speed machining provides an efficient approach for machining Inconel 718 with high quality and high efficiency. For high-speed milling of Inconel 718 curved surface, the geometrical characteristics are changing continuously leading to a sharp fluctuation of cutting force, which will aggravate the tool wear. As the wear mechanism of coated cutting tool is seriously affected by the cutting tool geometrical parameters, suitable geometrical parameters of cutting tool should be selected to avoid the cutting tool from being worn out very quickly. In this study, the influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface is investigated with coated cutting tool, and the cutting force in milling process is also analyzed. The results show that the cutting force variation can manifest the tool wear degree, and the failure type of coated cutting tool in plane milling and curved surface milling after the same cutting length is different. Furthermore, the cutting tool geometrical parameters seriously affect the tool wear and the tool life in high-speed milling of Inconel 718 curved surface. Concretely, the small rake angle has greater strength and has superiority, the relief angle increasing can enhance the tool life, and the tool life is decreased with the increasing of helix angle for the cutting tool, whose helix angle is larger than 30°. This study provides a theoretical basis for cutting tool wear mechanism and cutting tool geometrical parameter selection in high-speed milling of Inconel 718 curved surface, so as to guarantee the machining efficiency in high-speed milling of Inconel 718 curved surface.

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