Tool Wear of PVD Coated Carbide Inserts in High Speed Turning Inconel 718

2010 ◽  
Vol 26-28 ◽  
pp. 988-992
Author(s):  
Xin Yu Song ◽  
Jun Zhao
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Inconel 718 ◽  
High Speed ◽  
High Hardness ◽  
High Wear Resistance ◽  
Coating Delamination ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Notch Wear

TiAlN/TiN multilayer PVD coated carbide is one of the dominant tool materials for the turning applications of Inconel 718 due to its high hardness, high wear resistance, and high thermal stability. The results of a thorough investigation on TiAlN/TiN multilayer PVD coated carbide inserts were presented for turning Inconel 718. The tool wear of the PVD coated carbide inserts were tested and analyzed at different cutting speeds from 50m/min to 90m/min and different feed rates from 0.1mm/r to 0.4mm/r. The wear patterns and wear mechanisms of PVD coated carbide were analyzed. Results show that the dominant wear patterns are rake face wear, flank wear, micro-chipping, coating delamination, notch wear, built-up edge and breakage. The main wear mechanisms are adhesion, diffusion, abrasive and oxidation.

Failure Mechanisms of Carbide Tool in High Speed Milling of Inconel 718

2010 ◽  
Vol 97-101 ◽  
pp. 1920-1924 ◽  
Author(s):  
Xin Yu Song ◽  
Jun Zhao
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
High Hardness ◽  
High Wear Resistance ◽  
Thermal Crack ◽  
Cutting Depth ◽  
Nickel Based Superalloy ◽  
Diffusion Wear ◽  
Coating Delamination ◽  
Coated Carbide

TiAlN/TiN multilayer PVD coated carbide is one of the dominant tool materials for the milling applications of Inconel 718 due to its high hardness, high wear resistance, and high thermal stability. In this paper a study was undertaken to investigate the wear of TiAlN/TiN multilayer PVD-coated carbide tools during milling of nickel-based superalloy Inconel 718 at high speeds. The wear patterns and wear mechanisms were analyzed. Results show that the dominant wear patterns were coating delamination, thermal crack, micro-chipping，chatter marks and breakage. When the cutting depth was 1mm, the coated tool was predominantly subjected to adhesion and diffusion wear throughout the duration of cutting. Adhesive wear on one hand accelerated the extension of thermal crack, on the other hand promoted the diffusion wear. When the cutting depth was 3mm, the tool life was determined by chatter which could lead to failure of the cutting tool in very short time.

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.

scholarly journals Tool Condition Monitoring in Hard Turning of Inconel 718 by using Vibration Technique

2019 ◽  
Vol 8 (11) ◽  
pp. 1143-1147
Keyword(s):  
Tool Wear ◽  
Condition Monitoring ◽  
Inconel 718 ◽  
Hard Turning ◽  
High Hardness ◽  
Tool Condition Monitoring ◽  
Depth Of Cut ◽  
Vibration Signals ◽  
Tool Condition ◽  
Coated Carbide

In various machining processes, the vibration signals are studied for tool condition monitoring often referred as wear monitoring. It is essential to overcome unpredicted machining trouble and to improvise the efficiency of the machine. Tool wear is a vital problem in materials such as nickel based alloys as they have high hardness ranges. Though they have high hardness, a nickel based alloy Inconel 718 with varying HRC (51, 53, and 55), is opted as work material for hard turning process in this work. Uncoated and coated carbide tools are employed as cutting tools. Taguchi’s L9 orthogonal array is considered by taking hardness, speed, feed and depth of cut as four input parameters, the number of experiments and the combinations of parameters for every run is obtained. The vibration signals are recorded at various stages of cutting, till the tool failure is observed. Taking this vibration signal data as input to ANOVA and Grey relation analysis (GRA) which categorizes the optimal and utmost dominant features such as Root Mean Square (RMS), Crest Factor (CF), Skewness (Sk), Kurtosis (Ku), Absolute Deviation (AD), Mean, Standard Deviation (SD), Variance, peak, Frequency and Time in the tool wear process

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.

Experimental Investigation on Tool Wear when End-Milling Inconel 718 with Coated Carbide Inserts

2011 ◽  
Vol 188 ◽  
pp. 410-415 ◽  
Author(s):  
Yuan Wei Wang ◽  
Jian Feng Li ◽  
Z.M. Li ◽  
Tong Chao Ding ◽  
Song Zhang
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Coated Carbide ◽  
Carbide Inserts

In this paper, some experiments were conducted to investigate tool wear when end-milling Inconel 718 with the TiAlN-TiN PVD coated carbide inserts. The worn tools were examined thoroughly under scanning electron microscope (SEM) with Energy Dispersive X-ray Spectroscopy and 3D digital microscope to expatiate tool wear morphologies and relevant mechanisms. The flank wear was uniformity in finishing milling process, and the average flank wear were selected as the criterion to study the effects of cutting parameters (cutting speed, feed per tooth, radial depth of cut, and axial depth of cut) on tool wear. Finally, the optimal combination of the cutting parameters for the desired tool life is obtained.

scholarly journals Comparision of Dominant Features Identification for Tool Wear in Hard Turning of Inconel 718 by Using Vibration Analysis

2019 ◽  
Vol 69 (4) ◽  
pp. 1-8
Author(s):  
Dasari Kondala Rao ◽  
Kolla Srinivas
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Hard Turning ◽  
High Hardness ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Absolute Deviation ◽  
Vibration Signals ◽  
Wear Process ◽  
Coated Carbide

AbstractIn various machining processes, the vibration signals are studied for tool condition monitoring often referred as wear monitoring. It is essential to overcome unpredicted machining trouble and to improvise the efficiency of the machine. Tool wear is a vital problem in materials such as nickel based alloys as they have high hardness ranges. Though they have high hardness, a nickel based alloy Inconel 718 with varying HRC (51, 53, and 55), is opted as work material for hard turning process in this work. Uncoated carbide, coated carbide and ceramic tools are employed as cutting tools. Taguchi’s L9 orthogonal array is considered by taking hardness, speed, feed and depth of cut as four input parameters, the number of experiments and the combinations of parameters for every run is obtained. The vibration signals are recorded at various stages of cutting, till the tool failure is observed. Taking this vibration signal data as input to ANOVA and Grey relation analysis (GRA) which categorizes the optimal and utmost dominant features such as Root Mean Square (RMS), Crest Factor (CF), Skewness (Sk), Kurtosis (Ku), Absolute Deviation (AD), Mean, Standard Deviation (SD), Variance, peak, Frequency and Time in the tool wear process.

Tool wear mechanisms of PcBN in machining Inconel 718: Analysis across multiple length scale

CIRP Annals ◽  
2021 ◽  
Author(s):  
Volodymyr Bushlya ◽  
Filip Lenrick ◽  
Axel Bjerke ◽  
Hisham Aboulfadl ◽  
Mattias Thuvander ◽  
...  
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Inconel 718 ◽  
Length Scale ◽  
Tool Wear Mechanisms ◽  
Multiple Length Scale
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