Influence of Tool Flank Wear on Surface Integrity in Orthogonal Milling of Powder Metallurgy Superalloy

2012 ◽  
Vol 723 ◽  
pp. 182-187
Author(s):  
Jin Du ◽  
Zhan Qiang Liu
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Flank Wear ◽  
White Layer ◽  
Micro Hardness ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
White Layer Thickness ◽  
Cemented Carbide Tools ◽  
Coated Cemented Carbide

Tool flank wear has the significant effects on machined surface integrity. The influences of tool flank wear on the cutting forces, surface roughness, microhardness and white layer thickness are investigated in this paper through orthogonal milling experiments. FGH95 powder metallurgy (PM) superalloys are machined with coated cemented carbide tools in the milling experiments. The experiment results show that with the increasing of tool flank wear, cutting force, surface roughness and white layer thickness increase. However, the machined surfaces micro-hardness aggravates with the increase of tool flank wear. It is found that, the machined surface roughness, micro-hardness and white layer increase dramatically especially when the tool flank wear exceeds 0.3mm. A conclusion is then be drawn that, the maximum acceptable tool flank wear land is 0.3mm from the view point of surface integrity when FGH95 PM superalloy is machined with coated cemented carbide tools.

scholarly journals Effects of Tool Wear on Machined Surface Integrity During Milling of Inconel 718

2021 ◽  
Author(s):  
Liang Tan ◽  
Changfeng Yao ◽  
Dinghua Zhang ◽  
Minchao Cui ◽  
Xuehong Shen
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Machined Surface Integrity

Abstract This paper investigates the effects of tool wear on the machined surface integrity characteristics, including the surface roughness, surface topography, residual stress, microhardness and microstructure, during ball-end milling of Inconel 718. Tool wear, tool lifetime, and cutting force are measured. In addition, a two-dimensional finite element-based model is developed to investigate the cutting temperature distribution in the chip–tool–workpiece contact area. Results show that the ball nose end mill achieves tool lifetime of approximately 350 min. The cutting forces increase sharply with a greater tool flank wear width, while the highest cutting temperature has a decreasing tend at a flank wear width of 0.3 mm. Higher tool flank wear width produces larger surface roughness and deteriorative surface topography. A high-amplitude (approximately −700 MPa) and deep layer (approximately 120 mm) of compressive residual stress are induced by a worn tool with 0.3 mm flank wear width. The surface microhardness induced by new tool is larger than that induced by worn tool. Plastic deformation and strain streamlines are observed within 10 mm depth beneath the surface. The results in this paper provide an optimal tool wear criterion which integrates the surface integrity requirements and the tool lifetime for ball-end finish milling of Inconel 718.

Analysis of Reversible Fine Machining Sequence Effect on Surface Integrity

2006 ◽  
Vol 315-316 ◽  
pp. 391-395
Author(s):  
Wen Ge Wu ◽  
Si Qin Pang ◽  
Zhan Qiang Liu
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Surface Integrity ◽  
Machining Process ◽  
Processing Route ◽  
Machining Accuracy ◽  
Machining Efficiency ◽  
Micro Hardness ◽  
Rough Machining ◽  
Machined Surface

Reversible cutting method is a new research thesis proposed to shorten processing route, decrease tool number and handling time, increase machining efficiency. The aim of the presented work was to analysis the effects of reversible fine machining sequence on surface integrity in machined layer. Nonlinear hardening during reverse loading and the change of the Bauschinger effect factor with plastic strain were properly taken into account. In experiments, the residual stresses have been measured using the X-ray diffraction technique (at the surface of the workpiece and in depth). Moreover, micro-hardness and surface roughness of machined surface are presented. Experimental data for the range of cutting parameters tested showed that the reversible fine machining produce the tensile residual stresses at the surface, which are critical in the performance of the machined components. The experimental results of micro-hardness of reversible fine machining technique are smaller than that of general fine machining show that decreased plastic deformation of the surface layer and work-hardening. Surface roughness of machined surface with reversible finishing is discussed. Research results indicted that it can be adopted such planning which rough machining during advance stroke and fine machining or semi-finishing during return stroke in machining process. In this way, it has such advantages that increase machining efficiency and machining accuracy, decrease bending deformation.

scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

Experimental Study on Turning Nickel-Based Superalloy GH4033 with Coated Cemented Carbide Tools

2014 ◽  
Vol 800-801 ◽  
pp. 191-196
Author(s):  
Bin Zhao ◽  
Han Lian Liu ◽  
Chuan Zhen Huang ◽  
Bin Zou ◽  
Hong Tao Zhu
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Failure Modes ◽  
Flank Wear ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Nickel Based Superalloy ◽  
Coated Tool ◽  
Optimal Cutting Parameters ◽  
Coated Cemented Carbide

The nickel-based superalloy GH4033 is one of the difficult-to-cut materials. In order to investigate the machinability of GH4033, the tool cutting performance, tool failure modes, tool life and the relationships between surface roughness and tool flank wear were studied by using different coated cemented carbide cutting tools under dry cutting. Aiming at the amount of metal removal combining with the tool life and surface quality, the better cutting tool coating type and optimal cutting parameters were obtained through the orthogonal experiments. The results showed that the cutting performance of TiCN coated tool (GC4235) was better than that of TiAlN coated tool (JC450V). With these two kinds of tools, the machined surface roughness decreased to a minimum value and then increased with the increase of flank wear. When cutting GH4033, the main wear mechanism for both of the two types of tools included adhesive wear, diffusive wear, abrasive wear, edge wear and coating peeling.

Surface integrity of quenched steel 1045 machined by CBN grinding wheel and SiC grinding wheel

2017 ◽  
Vol 8 (2) ◽  
pp. 179-187 ◽  
Author(s):  
Kankan Ji ◽  
Xingquan Zhang ◽  
Shubao Yang ◽  
Liping Shi ◽  
Shiyi Wang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Compressive Stress ◽  
Surface Integrity ◽  
Grinding Wheel ◽  
Micro Hardness ◽  
Content Type ◽  
Quenched Steel ◽  
Cut Depth ◽  
Cbn Grinding Wheel

Purpose The purpose of this paper is to evaluate surface integrity of quenched steel 1045 ground drily by the brazed cubic boron nitride (CBN) grinding wheel and the black SiC wheel, respectively. Surface integrity, including surface roughness, sub-surface hardness, residual stresses and surface morphology, was investigated in detail, and the surface quality of samples ground by two grinding wheels was compared. Design/methodology/approach In the present work, surface integrity of quenched steel 1045 machined by the CBN grinding wheel and the SiC wheel was investigated systematically. All the specimens were machined with a single pass in the down-cutting mode of dry condition. Surface morphology of the ground specimen was observed by using OLYMPUS BX51M optical microscopy. Surface roughness of seven points was measured by using a surface roughness tester at a cut-off length of 1.8 mm and the measurement traces were perpendicular to the grinding direction. Sub-surface micro-hardness was measured by using HVS-1000 digital micro-hardness tester after the cross-section surface was polished. The residual stress was tested by using X-350A X-ray stress analyzer. Findings When the cut depth is increased from 0.01 to 0.07 mm, the steel surface machined by the CBN wheel remains clear grinding mark, lower roughness, higher micro-hardness and higher magnitude of compressive stress and fine microstructure, while the surface machined by the SiC grinding wheel becomes worse with increasing of cut depth. The value of micro-hardness decreases, and the surface roughness increases, and the surface compressive stress turns into tensile stress. Some micro-cracks and voids occur when the sample is processed by the SiC grinding wheel with cut depth 0.07 mm. Originality/value In this paper, the specimens of quenched steel 1045 were machined by the CBN grinding wheel and the SiC wheel with various cutting depths. The processing quality resulted from the CBN grinding wheel is better than that resulted from the SiC grinding wheel.

Evaluation of Surface Integrity in Electrochemical Micromachining of A286 Super alloy

2021 ◽  
Author(s):  
Rajkeerthi E ◽  
Hariharan P
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Integrity ◽  
Research Work ◽  
Machining Process ◽  
Electrochemical Micromachining ◽  
Dissolution Mechanism ◽  
Machined Surface ◽  
Micro Holes ◽  
Super Alloy

Abstract Surface integrity of micro components is a major concern particularly in manufacturing industries as most geometry of the products must meet out necessary surface quality requirements. Advanced machining process like electrochemical micro machining possess the capabilities to machine micro parts with best surface properties exempting them from secondary operations. In this research work, different electrolytes have been employed for producing micro holes in A286 super alloy material to achieve the best surface quality and the measurement of surface roughness and surface integrity to evaluate the machined surface is carried out. The machined micro hole provides detailed information on the geometrical features. A study of parametric analysis meant for controlling surface roughness and improvement of surface integrity has been made to find out the suitable parameters for machining. The suitability of various electrolytes with their dissolution mechanism and the influence of various electrolytes have been thoroughly studied. Among the utilized electrolytes, EG + NaNO3 electrolyte provided the best results in terms of overcut and average surface roughness.

scholarly journals An Investigation To Achieve a Good Surface Integrity in WEDM of Ti-6242 Super Alloy

2021 ◽  
Author(s):  
Sonia Ezeddini ◽  
Wajdi Rajhi ◽  
Mohamed Boujelbene ◽  
Emin Bayraktar ◽  
Sahbi Ben Salem
Keyword(s):  
Surface Roughness ◽  
Pulse Duration ◽  
Surface Integrity ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Good Surface ◽  
Pulse On Time ◽  
Super Alloy

Abstract Ti-6242 is a super alloy which exhibits the best creep resistance among available titanium alloys and is widely used in the manufacture by WEDM of aircraft engine turbomachinery components. However, the final quality of wire EDMed surface is a great challenge as it is affected by various factors that need optimization for surface integrity and machine efficiency improvement. The aim of this study is to investigate the effect of a set of cutting process parameters such as pulse on time (Ton), servo voltage (U), feed rate (S) and flushing pressure (p) on surface roughness (SR) when machining Ti-6242 super alloy by WEDM process using a brass tool electrode and deionized water as a dielectric fluid. WEDM experiments were conducted, and SR (Ra) measurement was carried out using a 3D optical surface roughness-meter (3D–SurfaScan). As a tool to optimize cutting parameters for SR improvement, Taguchi's signal‐to‐noise ratio (S/N) approach was applied using L9 (3^4) orthogonal array and Lower-The-Better (LTB) criteria. Substantially, the findings from current investigation suggest the application of the values 0.9 µs, 100V, 29 mm/min, and 60 bar for Ton, U, S and p cutting parameters, respectively, for producing a good surface finish quality. Percent contributions of the machining parameters on SR (Ra) assessed based on ANOVA analysis are 62.94%, 20.84%, 11.46% and 4.74% for U, S, Ton and p, respectively. Subsequently, accurate predictive model for SR (Ra) is established based on response surface analysis (RSA). The contour plots for SR (Ra) indicate that when flushing pressure p converges to a critical value (80 bar), a poor-quality surface finish is highly expected with the excessive increase in U and S. Electron microscope scanning (SEM) observations have been performed on machined surface for a wide range of cutting parameters to characterize wire EDMed surface of Ti-6242. SEM micrographs indicate that the machined surface acquires a foamy structure and shows white layer and machining-induced damage that the characteristics are highly dependent on cutting parameters. At high servo-voltage, the decrease in pulse on time Ton and feed rate S results in a large decrease in overall machining-induced surface damage. Moreover, for high servo-voltage and feed rate levels, it has been observed that pulse on time could play a role of controlling the surface microcracks density. In fact, the use of a low pulse duration of cut combined with high servo-voltage and feed rate has been shown to inhibit surface microcracks formation giving the material surface a better resistance to cracking than at high pulse duration.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

Influence of Cutting Speed on Surface Plastic Deformation and White Layer Formation of FGH95

2013 ◽  
Vol 589-590 ◽  
pp. 70-75 ◽  
Author(s):  
Jin Du ◽  
Zhan Qiang Liu
Keyword(s):  
Plastic Deformation ◽  
Surface Integrity ◽  
White Layer ◽  
High Reliability ◽  
Cutting Speed ◽  
Surface Plastic Deformation ◽  
Surface Plastic ◽  
Layer Formation ◽  
Machined Surface ◽  
White Layer Formation

The superalloy parts in the aeronautical field demand high reliability, which is largely related to surface integrity. Surface integrity generally includes three parameters, such as geometric parameter, mechanical parameter and metallurgical parameter. The paper presents the influence of cutting speed on surface plastic deformation and white layer formation through orthogonal milling of FGH95 superally material. The influence of cutting speed on grain refinement of machined surface is also investigated. It is found that cutting speed has significantly effect on the surface metallurgical characteristic microstructure. The increasing of cutting speed creates severer plastic deformation. Surface plastic shear strain increases with the increasing of cutting speed, while the depth of plastic deformation decreases on contrary. White layer thickness is increased with the increasing of cutting speed. Through statistical analysis for grains number, it can be drawn that the higher the cutting speed, the more serious grains refinement.

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