Performance of Alloyed CVD-Coated and PVD-Coated Carbide Tools in Dry Machining Nickel Based Alloy Inconel718

2012 ◽  
Vol 426 ◽  
pp. 118-121
Author(s):  
Dong Gao ◽  
Zhao Peng Hao ◽  
Rong Di Han ◽  
Yan Li Chang
Keyword(s):  
Thermal Conductivity ◽  
Cutting Force ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Tool Material ◽  
Dry Machining ◽  
Nickel Based Alloy ◽  
Tools Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

Nickel-based alloy Inconel718 is a difficult-to-cut material due to lower thermal conductivity, affinity to react with tool material, the cutting tools wear very rapidly due to the high cutting temperature and high cutting force. It is important to choose tool material reasonably. In this paper, cutting performance of the multi-layer CVD-coated (TiN/Al2O3/TiC) tool and PVD-coated (TiAlN) tool were evaluated by cutting temperature, cutting force, tool wear and tool life. The results showed that PVD-coated (TiAlN) tool was suitable for cutting Inconel718.

Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

2012 ◽  
Vol 497 ◽  
pp. 94-98
Author(s):  
Yang Qiao ◽  
Xiu Li Fu ◽  
Xue Feng Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Failure Mechanisms ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

scholarly journals A Fuzzy Evaluation of Tool Materials in the Turning of Marine Steels

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1710
Author(s):  
Qingzhong Xu ◽  
Jichen Liu ◽  
Gangjun Cai ◽  
Dewen Jiang ◽  
Jian Zhou
Keyword(s):  
Surface Roughness ◽  
Evaluation Method ◽  
Cutting Temperature ◽  
Tool Material ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Fuzzy Evaluation ◽  
Cemented Carbide Tools ◽  
Coated Carbide ◽  
Coated Carbide Tools

To recommend one suitable tool material for the cutting of marine steels under special conditions and requirements in emergency rescues of capsized steel ships, the cermet tools, cemented carbide tools and coated carbide tools were evaluated using a fuzzy evaluation method concerning cutting force, cutting temperature, surface roughness and tool wear. Experimental results indicate that the tool cutting performance was diverse and difficult to evaluate with a single evaluation index. The cemented carbide tools presented bad cutting performance with severe wear. Compared with the cemented carbide tools, the cermet tools showed excellent wear resistance with about 60.3% smaller tool flank wear value and good surface quality with about 46.8% smaller surface roughness. The coated carbide tools presented low cutting temperatures about 15.6% smaller than those of the cermet tools. The result of fuzzy evaluation demonstrates that the cermet tools presented the best cutting performance, followed by the coated carbide tools, and then the cemented carbide tools. The cermet tools are recommended to cut marine steels in emergency rescues of capsized steel ships.

Simulation of Machining of Incoloy 907 Based on Thermodynamical Constitutive Equation

2013 ◽  
Vol 631-632 ◽  
pp. 681-685
Author(s):  
Fang Shao ◽  
Fa Qing Li ◽  
Hai Ying Zhang ◽  
Xuan Gao
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Tool Material ◽  
High Reactivity ◽  
Good Prediction ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting ◽  
Cutting Tool Materials

Aero-engine alloys (also as known as superalloys)are known as difficult-to-machine materials, especially at higher cutting speeds, due to their several inherent properties such as low thermal conductivity and their high reactivity with cutting tool materials. In this paper a finite element analysis (FEA) of machining for Incoloy907 is presented. In particular, the thermodynamical constitutitve equation(T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and cutting force are predicted. The comparison between the predicted and experimental cutting temperature and cutting force are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and cutting force can be achieved by the method of FEA with thermodynamical constitutitve equation.

An Investigation on Machining Power of EN-AC 48000 Aluminum Alloy Used in Automotive and Aerospace Industries

2009 ◽  
Vol 83-86 ◽  
pp. 704-710 ◽  
Author(s):  
H. Shahali ◽  
Hamid Zarepour ◽  
Esmaeil Soltani
Keyword(s):  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Dimensional Accuracy ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Essential Parameter ◽  
Cutting Velocity ◽  
Coated Carbide

In this paper, the effect of machining parameters including cutting velocity, feed rate, and tool material on machining power of EN-AC 48000 aluminium alloy has been studied. A L27 Taguchi's standard orthogonal array has been applied as experimental design to investigate the effect of the factors and their interaction. Twenty seven machining tests have been accomplished with two random repetitions, resulting in fifty four experiments. EN-AC 48000 is an important alloy in automotive and aerospace industries. Machining of this alloy is of vital importance due to build-up edge and tool wear. Machining power is an essential parameter affecting the tool life, dimensional accuracy, and cutting efficiency. Three types of cutting tools including coated carbide (CD 1810), uncoated carbide (H10), and polycrystalline diamond (CD10) have been used in this study. Statistical analysis has been employed to study the effect of factors and their interactions using ANOVA analysis. Moreover, optimal factor levels have been presented using signal to noise ratio (S/N) analysis. Also, regression model have been provided to predict the machining power. Finally, the results of confirmation tests have been presented to verify and compare the adequacy of the predictive models.

Comparative assessment between AlTiN and AlTiSiN coated carbide tools towards machinability improvement of AISI D6 steel in dry hard turning

2021 ◽  
pp. 095440622110373
Author(s):  
Anshuman Das ◽  
Miyaz Kamal ◽  
Sudhansu Ranjan Das ◽  
Saroj Kumar Patel ◽  
Asutosh Panda ◽  
...  
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Chip Morphology ◽  
Comparative Assessment ◽  
Carbide Tool ◽  
Crater Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

AISI D6 (hardness 65 HRC) is one of the hard-to-cut steel alloys and commonly used in mould and die making industries. In general, CBN and PCBN tools are used for machining hardened steel but its higher cost makes the use for limited applications. However, the usefulness of carbide tool with selective coatings is the best substitute having comparable tool life, and in terms of cost is approximately one-tenth of CBN tool. The present study highlights a detailed analysis on machinability investigation of hardened AISI D6 alloy die steel using newly developed SPPP-AlTiSiN coated carbide tools in finish dry turning operation. In addition, a comparative assessment has been performed based on the effectiveness of cutting tool performance of nanocomposite coating of AlTiN deposited by hyperlox PVD technique and a coating of AlTiSiN deposited by scalable pulsed power plasma (SPPP) technique. The required number of machining trials under varied cutting conditions (speed, depth of cut, feed) were based on L16 orthogonal array design which investigated the crater wear, flank wear, surface roughness, chip morphology, and cutting force in hard turning. Out of the two cutting tools, newly-developed nanocomposite (SPPP-AlTiSiN) coated carbide tool promises an improved surface finish, minimum cutting force, longer tool life due to lower value of crater & flank wears, and considerable improvement in tool life (i.e., by 47.83%). At higher cutting speeds, the crater wear length and flank wear increases whereas the surface roughness, crater wear width and cutting force decreases. Chip morphology confirmed the formation of serrated type saw tooth chips.

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. 

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.

Evaluation of Thermal Effects in Turning Processes: Numerical and Experimental Approach

2019 ◽  
Author(s):  
Aruna Prabha Kolluri ◽  
Srinivasa Prasad Balla ◽  
Satya Prasad Paruchuru
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Tool Material ◽  
Maximum Error ◽  
Tool Wear Mechanism ◽  
Coated Carbide

Abstract The 3D Finite element method (FEM) is an efficient tool to predict the variables in the cutting process, which is otherwise challenging to obtain with the experimental methods alone. The present study combines both experimental findings and finite element simulation outcomes to investigate the effect of tool material on output process variables, such as vibrations, cutting temperature distribution and tool wear mechanism. Machining of popular aerospace materials like Ti-6Al-4V and Al7075 turned with coated and uncoated tools are part of the investigation. The authors choose the orthogonal test, measured vibrations and cutting temperatures and used FE simulations to carry out the subsequent validations. This study includes the influence of the predicted heat flux and temperature distribution on the tool wear mechanism. The main aim of this study is to investigate the performance quality of uncoated and coated carbide tools along with its thermal aspects. Comparison of experiment and simulation outcomes shows good agreement with a maximum error of 9.02%. It has been noted that the increase of cutting temperature is proportional to its cutting speed. As the cutting speed increases, it is observed that vibration parameter and flank wear value also increases. Overall, coated carbide turning insert tool is the best method for metal turning with higher rotational speeds of the spindle.

Simulation of Machining of Incoloy 907 with Thermodynamical Constitutive Equation

2013 ◽  
Vol 634-638 ◽  
pp. 1790-1793
Author(s):  
Fang Shao ◽  
Hai Ying Zhang ◽  
Zhi Jun Fan
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Tool Material ◽  
High Reactivity ◽  
Good Prediction ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting ◽  
Cutting Tool Materials

Aero-engine alloys (also as known as superalloys)are known as difficult-to-machine materials, especially at higher cutting speeds, due to their several inherent properties such as low thermal conductivity and their high reactivity with cutting tool materials. In this paper a finite element analysis (FEA) of machining for Incoloy907 is presented. In particular, the thermodynamical constitutitve equation(T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and cutting force are predicted. The comparison between the predicted and experimental cutting temperature and cutting force are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and cutting force can be achieved by the method of FEA with thermodynamical constitutitve equation.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

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