scholarly journals High-Pressure Cooling in Finishing Turning of Haynes 282 Using Carbide Tools: Haynes 282 and Inconel 718 Comparison

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 1916
Author(s):  
Antonio Díaz-Álvarez ◽  
José Díaz-Álvarez ◽  
José Luis Cantero ◽  
Mª Henar Miguélez
Keyword(s):  
High Pressure ◽  
Comparative Analysis ◽  
Tool Wear ◽  
Tool Life ◽  
Inconel 718 ◽  
High Pressures ◽  
Cutting Speed ◽  
Heat Removal ◽  
Cutting Fluids ◽  
Coated Carbide

Despite the interest of industry in nickel-based superalloys and its main features (high temperatures resistance, hardness, low thermal conductivity, among others), even today they are still materials that are difficult to cut. Cutting tools withstand both high pressures and temperatures highly localized at the cutting area because of the elevated work hardening of the alloy and the problems for the cutting fluid to access the region, with the consequent strong tool wear. The use of cutting fluids at high pressures improves coolant access and heat removal. This paper analyzed the machining of Haynes 282 alloy by means of coated carbide tools under high-pressure cutting fluids at finishing conditions. Tests were developed at different cutting speeds and feeds quantifying the machining forces, surface roughness, tool wear, and tool life. Values of 45.9 min and Ra between 2 µm and 1 µm were obtained in this study for tool life and roughness, respectively, for the combination of cutting speed 50 m/min and feed 0.1 mm/rev. Likewise, a comparative analysis is included with the results obtained in previous works developed by the authors relating to the finishing turning of Haynes 282 and Inconel 718 under conventional pressure cooling. The comparative analysis with Inconel 718 is included in the study due to its importance within the nickel base superalloys being widely used in industry and widely analyzed in scientific literature.

The Effects of TiAlN and TiN Coating during End Milling of INCONEL 718

2014 ◽  
Vol 564 ◽  
pp. 566-571
Author(s):  
K. Kamdani ◽  
Sulaiman Hasan ◽  
Mohd Amri Lajis
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Speed ◽  
Extreme Condition ◽  
Carbide Tool ◽  
Coated Carbide Tool ◽  
Coated Carbide

Inconel 718 is a registered trademark of Special Metals Corporation that refers to a family of austenitic nickel-chromium-based super alloys. This material usually being used or operate in high temperature and extreme condition like aerospace industry, turbocharger rotors and seals. This research presents an experimental study of the cutting force variation, surface roughness, tool life and tool wear in end milling Inconel 718. The experimental results showed that flank wear was the predominant failure mode affecting tool life for TiAlN and TiN coated carbide tool. TiAlN is the better coated tool than TiN because it produce better surface finish and resultant force. Feed rate is one of the parameter that effecting results in this experiment. The higher feed rate will shorten the life of the tool. Although for the cutting condition, the situation is quite different where the proper cutting speed will maintain the tool life and tool wear for cutting tool. The overall study shows that TiAlN coated carbide tool with cutting speed 100 m/min, depth of cut 0.5 mm and feed rate 0.1 mm/tooth is the optimum parameter in this experiment.

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

2010 ◽  
Vol 33 ◽  
pp. 173-176
Author(s):  
X.Y. Wang ◽  
S.Q. Pang ◽  
Q.X. Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Experimental Research ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Life Testing ◽  
Processing Efficiency ◽  
Comparative Tests ◽  
Coated Carbide ◽  
Coated Carbide Tools

The aim of this work is to investigate the machinability of new coated carbide cutting tools that are named C7 plus coatings under turning of superalloy GH2132. This achieved by analysis of tool life at different cutting conditions .Investigations of tool wear and tool life testing are intended to establish T-V formulas, and then analyzed the characteristics of coating . Through a series of comparative tests, Using TiAlN coatings as the contrast materialthe results show that the new coating tools that are named C7 plus coatings are suitable for cutting superalloy GH2132. The cutting speed and processing efficiency can be increased effectively.

Turning of SAE 1050 Steel With Vegetable Base Cutting Fluid

2012 ◽  
Author(s):  
Rosemar Batista da Silva ◽  
Álisson Rocha Machado ◽  
Déborah de Oliveira Almeida ◽  
Emmanuel O. Ezugwu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Manufacturing Companies ◽  
Machining Performance ◽  
Increase Tool Life

The study of cutting fluid performance in turning is of great importance because its optimization characteristics has associated benefits such as improved tool life and overall quality of machined components as well as reduction in power consumption during machining. However, there are recent concerns with the use of cutting fluids from the environmental and health standpoints. Since environmental legislation has become more rigorous, the option for “green machining” attracts the interest of several manufacturing companies. It is important to consider the cost of machining which is associated with tool wear, depending on the cutting environment. The use of vegetable oil may be an interesting alternative to minimize the health and environmental problems associated with cutting fluids without compromising machining performance. This paper presents a comparative study of mineral and vegetable cutting fluids in terms of tool wear after turning SAE 1050 steel grade with cemented carbide cutting tools. Constant depth of cut of 2mm and variable cutting speed (200 and 350 m/min) and feed rate (0.20 and 0.32 mm/rev) were employed. Test results suggest that is possible to achieve improvement in machinability of the material and increase tool life by using vegetable cutting fluid during machining. Tool life increased by about 85% when machining with vegetable-based fluids compared to mineral-based fluids. Analysis of the worn tools, however, revealed a more uniform wear on the worn flank face when machining with mineral-based fluids.

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.

Analytical Study of the Effect of Heat Pipe Cooling in Machining

2005 ◽  
Author(s):  
Richard Y. Chiou ◽  
Vitaliy Aynbinder ◽  
L. G. Stepanskiy ◽  
Lin Lu ◽  
Shreepud Rauniar ◽  
...  
Keyword(s):  
Analytical Solution ◽  
Tool Wear ◽  
Heat Pipe ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Fluids ◽  
Tool Insert

Tool wear of machine tools and large usage of cutting fluids is one of the major problems in manufacturing. Cutting fluids are used to cool down the tool and have been shown to cause environmental problems in machine shops. Tool life and temperature have an inverse relationship, namely that the higher the temperature at the tool-chip interface is, the lower the tool life will be, and vice-versa. In this paper an innovative approach was taken to create an analytical solution to the effect of the embedded heat pipe on temperature of the tool and tool life. It has been well documented in the industry that the major factors that contribute to tool wear are the material properties of the tool insert and the work piece, cutting speed, depth of cut and feed rate. The analytical approach taken in this project is unique because it does not only take into account the complex boundary conditions of heat transfer but also the aforementioned factors and variety of possible cutting conditions. The analytical solution is in the form of set of equations which were developed to simulate the behavior of the tool insert under normal cutting conditions. Both cases, with and without heat-pipe were considered. The predicted temperature data was then compared to the existing experimental data, with very good results. In the end the project yields a quantitative evaluation on influence of mechanical properties of insert, work piece, heat pipe and cutting conditions on tool wear.

MQL Cutting of Inconel 718 with a Super Lattice Coating Tool

2005 ◽  
Vol 291-292 ◽  
pp. 433-438 ◽  
Author(s):  
Toshiyuki Obikawa ◽  
Y. Kamata
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Nickel Base Superalloy ◽  
Dry Cutting ◽  
Super Lattice ◽  
Air Supply ◽  
Coated Carbide ◽  
Cutting Point

MQL (Minimum Quantity Lubrication) technology was applied to finish-turning of a nickel base superalloy, Inconel 718, with a PVD coated carbide tool with a super lattice coating of TiN/AlN. Cutting lubricant used for MQL was a biodegradable synthesis ester, which was supplied to the cutting point with compressed air from the both sides of flank and rake faces of the tool. At a cutting speed of 1.0 m/s and an air supply pressure of 0.4 MPa, MQL cutting showed longer tool life and better surface finish than both the dry cutting and wet cutting. When increasing the pressure of the air supply from 0.40 MPa to 0.60 MPa, however, the corner wear, the most predominant wear in all the cutting conditions in this study, increased. When the cutting speed was increased to 1.5 m/s, the tool life in MQL decreased drastically. These results suggested that when finishing Inconel 718, the special care must be taken for choosing the pressure of air supply and cutting speed. The obtained results provided a useful understanding of the complicated influence of MQL on the cutting performance of Inconel 718.

Tool Wear of PVD Coated Carbide Tool when Finish Turning Inconel 718 under High Speed Machining

2010 ◽  
Vol 129-131 ◽  
pp. 1004-1008 ◽  
Author(s):  
M.Z.A. Yazid ◽  
C.H. Che Hassan ◽  
A.G. Jaharah ◽  
A.I. Gusri ◽  
M.S. Ahmad Yasir
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Nose Radius ◽  
Machining Processes ◽  
Finish Turning ◽  
Diffusion Wear ◽  
Flank Face ◽  
Coated Carbide

This paper reports the results of an experimental works, where Inconel 718, a highly corrosive resistant, nickel-based super alloy, was finish-turning under high speed conditions. The machining processes were carried out at three different cutting conditions (DRY, MQL 50 ml/h and MQL 100 ml/h), three levels of cutting speed (Vc=90, 120 and 150 m/min), two levels of feed rate (f=0.10 and 0.15 mm/rev) and two levels of cutting depth (d=0.30 and 0.50 mm). The tool wear and flank wear progression were monitored, measured and recorded progressively at various time intervals. The experiments indicated that MQL condition performs better than dry condition in term of tool life. Most of the tool failures during machining were due to gradual failure where abrasive and notching wear on the flank face was the dominant followed by, fracture on the flank edge and nose radius. Tool failure due to crater wear was not significant. Wear mechanism such as abrasive and adhesion were observed on the flank face and diffusion wear was observed on the rake face.

Tool life and tool wear during high-speed rough milling using alternative cutter path strategies

2003 ◽  
Vol 217 (9) ◽  
pp. 1295-1304 ◽  
Author(s):  
C K Toh
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Cutting Speed ◽  
Experimental Results ◽  
Peripheral Milling ◽  
H13 Steel ◽  
Cutter Path ◽  
Rough Milling ◽  
Coated Carbide

The paper is concerned with a feasibility study of tool life and tool wear when employing high depths of cut (between 10 and 20 mm) and different cutter path strategies in the high-speed milling (HSM) of hardened die/mould steel. Following a review of previous work, experimental data are presented on the peripheral milling of hardened AISI H13 steel (HRC 52) using raster, single-direction raster and offset machining strategies. Coated carbide corner-radius end mills with a diameter of 10mm were employed with a fixed cutting speed of 314m/min and a feed per tooth of 0.067mm. From the experimental results it was realized that a raster cutter path strategy (combination of up and down milling) combined with high-depth roughing achieved the lowest tool wear. The offset strategy achieved the lowest tool life at all axial depths of cut within the range investigated. The experimental results clearly show that cutter path strategies and axial depths of cut have a significant effect on the tool life and tool wear for the cutters employed.

Investigation on Wear Behavior and Chip Formation During Up-Milling and Down-Milling Operations for Inconel 718

2014 ◽  
Vol 66 (3) ◽  
Author(s):  
M. A. Hadi ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Inconel 718 ◽  
End Milling ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Milling Operations ◽  
Milling Operation ◽  
Coated Carbide

A comprehensive study and FEM simulation of ball nose end milling on tool wear behavior and chip formation had been performed on Inconel 718 (nickle-based superalloy) under minimum quantity lubricant (MQL) condition. In this paper, the investigation was focusing on the comparison of up-milling and down-milling operations using a multi-layer TiAlN/AlCrN-coated carbide inserts. A various cutting parameters; depth of cut, feed rate and cutting speed were considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear compared to up-milling operation. Chipping on cutting tool edge responsible to notch wear with prolong machining. It was observed that the chips formed in up-milling operation were segmented and continuous, meanwhile down-milling operation produced discontinuous type of chips.

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