Investigation of the Machinability of Inconel 718 in Room Temperature and Preheated Conditions

2011 ◽  
Vol 264-265 ◽  
pp. 1187-1192
Author(s):  
A.K.M. Nurul Amin ◽  
A. Fakhruzi Majed ◽  
M.K. Daud ◽  
Anayet Ullah Patwari ◽  
M.H. Ishtiyaq
Keyword(s):  
Inconel 718 ◽  
Room Temperature ◽  
End Milling ◽  
Chip Morphology ◽  
Material Surface ◽  
Work Piece ◽  
Aerospace Materials ◽  
Space Navigation ◽  
Preheating Temperature ◽  
Coated Carbide

Inconel 718 is widely used in the aviation, space, navigation and shipping industries because of its outstanding properties. The very mechanical characteristics that give this alloy the highly valued properties also make it one of the most difficult-to-machine aerospace materials. Due to the hardness of nickel-based super-alloys, such as Inconel 718, advanced tools like ceramics have been recommended to machine them. But ceramics are low conductive materials, and the heat generated during the machining of Inconel 718 transfers very slowly through them. The accumulation of generated heat on the cutting edges of ceramic tools causes many problems and sometime leads to premature tool failure. Hence in this study the effectiveness of PVD TiAlN coated carbide insert has been investigated. One approach to overcome the difficulties in machining of Inconel 718 is to use an external heat source to soften the work material surface layer to be removed in order to decrease its tensile strength. A new approach of preheating using inducting heating as an economical alternative to Laser Assisted Machining for end milling of Inconel 718 is presented in this paper. The machinability of Inconel 718 under varying conditions is evaluated by examining tool wear, surface roughness and chip morphology. With increasing work-piece preheating temperature, from room temperature to 420 °C, the advantages of Induction heating is demonstrated by an extended tool life and better surface finish due to more stable chip formation and elimination of micro and macro failure of the tool.

Machinability Improvement by Workpiece Preheating during End Milling AISI H13 Hardened Steel

2011 ◽  
Vol 264-265 ◽  
pp. 894-900 ◽  
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari ◽  
Nurhayati Ab. Razak
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Tool Life ◽  
Room Temperature ◽  
End Milling ◽  
Hardened Steel ◽  
Cutting Conditions ◽  
Preheating Temperature ◽  
Aisi H13 ◽  
Coated Carbide

Hardened materials like AISI H13 steel are generally regarded as s difficult to cut materials because of their hardness due to intense of carbon content, which however allows them to be used extensively in the hot working tools, dies and moulds. The challenges in machining steels at their hardened state led the way to many research works in amelioration its machinability. In this paper, preheating technique has been used to improve the machinability of H13 hardened steel for different cutting conditions. An experimental study has been performed to assess the effect of workpiece preheating using induction heating system to enhance the machinability of AISI H13. The preheated machining of AISI H13 for two different cutting conditions with TiAlN coated carbide tool is evaluated by examining tool wear, surface roughness and vibration. The advantages of preheated machining are demonstrated by a much extended tool life and stable cut as lower vibration/chatter amplitudes. The effects of preheating temperature were also investigated on the chip morphology during the end milling of AISI H13 tool steel, which resulted in reduction of chip serration frequency. The preheating temperature was maintained below the phase change temperature of AISI H13. The experimental results show that preheated machining led to appreciable increasing tool life compared to room temperature machining. Abrasive wear, attrition wear and diffusion wear are found to be a very prominent mechanism of tool wear. It has been also observed that preheated machining of the material lead to better surface roughness values as compared to room temperature machining.

EFFECT OF CUTTING PARAMETERS ON CUTTING ZONE IN CRYOGENIC HIGH SPEED MILLING OF INCONEL 718 ALLOY

2015 ◽  
Vol 77 (27) ◽  
Author(s):  
A. H. Musfirah ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Part Quality ◽  
Cutting Zone ◽  
Coated Carbide

In tribology phenomenon, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in ball end milling process. Experiments were performed using a multi-layer TiAlN/AlCrN-coated carbide inserts under cryogenic and dry cutting condition. A transient milling simulation model using Third Wave Advantedge has been done in order to gain in-depth understanding of the thermomechanical aspects of machining and their influence on resulted part quality. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can  decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining. Furthermore, the microstructure of machined workpiece revealed that cryogenic cooling also can reduce a plastic deformation at the cutting surface as compared with the dry machining. 

Progressive Tool Failure in High Speed End Milling of Inconel 718 with Coated Carbide Inserts

2011 ◽  
Vol 188 ◽  
pp. 32-37 ◽  
Author(s):  
An Hai Li ◽  
Jun Zhao ◽  
Z.Q. Pei ◽  
S.G. Guo
Keyword(s):  
Abrasive Wear ◽  
Inconel 718 ◽  
Adhesive Wear ◽  
End Milling ◽  
Failure Mechanisms ◽  
Cutting Speed ◽  
Fatigue Wear ◽  
Edge Chipping ◽  
Tool Failure ◽  
Coated Carbide

The failure progression of coated carbide tools in end milling of Inconel 718 superalloy was investigated. Tool wear was measured and failure mechanisms were discussed in the experimental process periodically. The experimental results indicated that the tool failure mechanisms were synergistic interaction among abrasive wear, adhesive wear, and fatigue wear. However, abrasive wear and adhesive wear were the main failure mechanisms at the beginning, fatigue wear prevailed the upper hand around the time when edge chipping appeared, and after edge chipping abrasive wear and adhesive wear dominated until the failure time. In addition, the macroscopic failure of the cutting tools is closely correlated to the nucleation and propagation of the crack under cyclic mechanical and thermal impact forces. Mechanical fatigue wear was the key form of fatigue wear at lower cutting speed, while at higher cutting speed thermal fatigue wear was the dominant fatigue wear.

A Two-Parameter Method to Monitor and Characterize Tool Wear in End Milling Inconel 718

2012 ◽  
Author(s):  
W. Li ◽  
Y. B. Guo
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Elevated Temperatures ◽  
Flank Wear ◽  
End Milling ◽  
Parameter Method ◽  
Manufacturing Cost ◽  
Cnc Machine ◽  
Coated Carbide ◽  
Two Parameter

Inconel 718 is among the most widely used superalloys in many industries. It is often used in very harsh conditions such as jet engines, combustors and nuclear reactors due to its high strength at elevated temperatures, high oxidation and corrosion resistance. Machining superalloy Inconel 718 has always been a challenging task due to its poor machinability including rapid work hardening, low thermal conductivity, and relatively short cutting tool life. The fast tool wear during cutting Inconel 718 results in longer production time, deteriorated surface integrity, and higher manufacturing cost. In this paper, an on-line optical tool monitoring system integrated with a CNC machine tool has been developed to examine tool wear evolutions in end milling Inconel 718 with PVD (Ti, Al) N/TiN-coated carbide insert. Three basic types of tool wear: flank wear, nose wear, and crater wear were examined and analyzed. A two-parameter method has been proposed to evaluate both flank wear and nose wear vs. cutting time.

Enhancement of Machinability of Inconel 718 in End Milling through Online Induction Heating of Workpiece

2011 ◽  
Vol 415-417 ◽  
pp. 420-423 ◽  
Author(s):  
AKM Nurul Amin ◽  
Mohammad Ishtiyaq Hossain ◽  
Anayet Ullah Patwari
Keyword(s):  
Tool Life ◽  
Induction Heating ◽  
Inconel 718 ◽  
End Milling ◽  
Heating Temperature ◽  
Phase Transformation Temperature ◽  
Life Tool ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Conventional Machining

Abstract. This paper presents the outcome of a study on heat assisted end milling of Inconel 718 using inducting heating technique conducted to enhance the machinability of the material. The heating temperature maintained below the phase transformation temperature was aimed at softening the top removable material layers. The experimental results of both conventional and heat assisted machining were compared. The machinability of Inconel 718 under these conditions was evaluated in terms of tool life, tool wear morphology and chatter. The advantages of Induction heating is demonstrated by an longer tool life and lower chatter. The study showed that preheated machining facilitates up to 80% increase of tool life over conventional machining conducted using TiAlN coated carbide inserts.

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.

scholarly journals Experimental investigations and finite element analysis of milling of Inconel 718 alloy

2021 ◽  
Vol 12 ◽  
pp. 21
Author(s):  
Akhil C. Kuriakose ◽  
Raman Balakrishnan ◽  
Harsh Vardhan ◽  
Krishnaraju Srinivasaraju Vijay Sekar
Keyword(s):  
Inconel 718 ◽  
End Milling ◽  
Chip Morphology ◽  
Milling Process ◽  
Experimental Investigations ◽  
High Temperature Strength ◽  
Inconel 718 Alloy ◽  
Element Analysis ◽  
The Family ◽  
Research Gap

Super-alloys encompass great challenges in machinability. One such alloy of much interest in applications is Inconel 718. Its increased hardness, low thermal diffusivity and high temperature strength make it desirable for applications, at the same time rendering its machining a demanding task. Extensive studies have been performed on machinability of Inconel 718, from the turning process stand-point. However, there is found to be a comparative dearth of work on the milling process. Taking into account the versatility of end-milling within the family of milling processes and the research gap, we found that a parametric optimization (aimed at minimum machining forces) of end-milling would be a meaningful effort. An experiment was conducted to study conditions that would help us achieve the same. In our further quest for optimization, chip morphology studies using SEM occupied a special place. Bearing in mind immense prediction capabilities of computer simulations based on FEA available today, we attempted process replication of the experimental work. The significant cutting forces were chosen as the benchmark factor for this purpose and proper attention was given to validation of the FEM created. Such FEM holds promise of being resourceful to drive up efficiency, with consequent spill-over to the production line.

Experimental Researching of Thermal - Assisted Milling with Induction on Surface Roughness of SKD11 Steel

2019 ◽  
Vol 889 ◽  
pp. 190-196
Author(s):  
Mac Thi Bich ◽  
Pham Thi Hoa ◽  
Banh Tien Long ◽  
Nguyen Duc Toan
Keyword(s):  
Surface Roughness ◽  
Room Temperature ◽  
Elevated Temperatures ◽  
End Milling ◽  
Heating Process ◽  
Work Piece ◽  
Technical Parameters ◽  
Roughness Model ◽  
Good Agreement

This paper presents experimental studied results about surface roughness during end milling SKD11 steel under room temperature and work-piece preheated condition. Conventional samples were first performed. The samples which are same technical parameters were then performed at elevated temperatures to evaluate effective of heating process on the surface roughness. Orthogonal array Taguchi method was used to experimental design. The results showed that the surface quality of product was significantly improved under thermal - assisted milling. The surface roughness model during machining at room and elevated temperatures were evaluated and showed a good agreement with result of experiments.

scholarly journals Optimization of Turning Process Parameters for Their Effect on En 8 Material Work piece Hardness by Using Taguchi Parametric Optimization Method

2012 ◽  
pp. 230-234
Author(s):  
Ashish Yadav ◽  
Ajay Bangar ◽  
Rajan Sharma ◽  
Deepak Pal
Keyword(s):  
Process Parameters ◽  
Tool Material ◽  
Optimization Method ◽  
Material Surface ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Parameters ◽  
Turning Process ◽  
Cylindrical Parts ◽  
Coated Carbide

A common method to manufacture parts to a specific dimension involves the removal of excess material by machining operation with the help of cutting tool. Turning process is the one of the methods to remove material from cylindrical and non-cylindrical parts. In this work the relation between change in hardness caused on the material surface due the turning operation with respect to different machining parameters like spindle speed, feed and depth of cut have been investigated. Taguchi method has been used to plan the experiments and EN 8 metal selected as a work piece and coated carbide tool as a tool material in this work and hardness after turning has been measured on Rockwell scale. The obtained experimental data has been analyzed using signal to noise and. The main effects have been calculated and percentage contribution of various process parameters affecting hardness also determined.

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