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.

End-Milling Machinability of Inconel 718

1996 ◽  
Vol 210 (1) ◽  
pp. 11-23 ◽  
Author(s):  
M Alauddin ◽  
M A El Baradie ◽  
M S J Hashmi
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Inconel 718 ◽  
End Milling ◽  
Milling Process ◽  
Machining Parameters ◽  
Life Tests ◽  
Life Values ◽  
Published Research ◽  
Carbide Inserts

Most published research works on machining Inconel 718 have been mainly concerned with turning, while the milling process has received little attention due to the complexity of the process. In this paper a series of end-milling experiments of Inconel 718 has been carried out in order to: (a) optimize cutting variables, (b) investigate tool life values and relationships and (c) investigate surface roughness. The machining parameters have been optimized by measuring cutting forces. Tool life tests have been carried out using carbide inserts and the surface roughness has been analysed.

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.

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.

Surface Integrity in Hot Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 500 ◽  
pp. 44-50 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim
Keyword(s):  
Induction Heating ◽  
Surface Integrity ◽  
Work Hardening ◽  
End Milling ◽  
Heating Temperature ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Aisi D2 ◽  
Hot Machining ◽  
Coated Carbide

This study presents experimental results of machined surface integrity of die material (AISI D2 hardened steel) when hot machining (induction heating) assisted end milling using coated carbide is applied. The aim of this work was to study the influence of induction heating temperature, cutting speed, and feed on the effects induced by hard milling on surface integrity (microhardness and work-hardening). Microhardness was measured to observe the distribution of the hardness beneath the surface and to determine the effect of induction heating on the micro-hardness distribution and work-hardening phenomena. The behaviour of microhardness induced in the subsurface region when end milling under room and induction heating cutting conditions using coated carbide inserts was also investigated. The surface integrity and subsurface alteration have been investigated by employing scanning electron microscope (SEM) and Vickers microhardness tester.

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.

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.

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.

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