An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts. J Mater Process Tech 180(1-3):296-304

Journal of Materials Processing Technology (Impact Factor: 2.24). 12/2006; 180(1). DOI: 10.1016/j.jmatprotec.2006.07.009
Source: OAI

ABSTRACT Inconel 718 is a difficult-to-cut nickel-based superalloy commonly used in aerospace industry. This paper presents an experimental study of the tool wear propagation and cutting force variations in the end milling of Inconel 718 with coated carbide inserts. The experimental results showed that significant flank wear was the predominant failure mode affecting the tool life. The tool flank wear propagation in the up milling operations was more rapid than that in the down milling operations. The cutting force variation along with the tool wear propagation was also analysed. While the thermal effects could be a significant cause for the peak force variation within a single cutting pass, the tool wear propagation was believed to be responsible for the gradual increase of the mean peak force in successive cutting passes.

Download full-text


Available from: Xiaoqi Chen, Apr 16, 2014
1 Follower
426 Reads
  • Source
    • "Research carried out by Bouzakis et al. [10] has shown that the kinematics of milling process (up-milling or down-milling), have significantly affects the stress distribution during the material removal and also the cutting performance. The results obtained through an experimental study done by Li et al. [2], shown that the tool flank wear propagation in the up milling operation is more rapid than that in the down milling operations. All these studies explained more insight of tool performance in down milling operation of Inconel 718. "
    [Show abstract] [Hide abstract]
    ABSTRACT: A comprehensive study and FEM simulation of ball nose end milling on tool wear behavior and chip formation had been performed on Inconel 718 (nickle-based superalloy) under minimum quantity lubricant (MQL) condition. In this paper, the investigation was focusing on the comparison of up-milling and down-milling operations using a multi-layer TiAlN/AlCrN-coated carbide inserts. A various cutting parameters; depth of cut, feed rate and cutting speed were considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear compared to up-milling operation. Chipping on cutting tool edge responsible to notch wear with prolong machining. It was observed that the chips formed in up-milling operation were segmented and continuous, meanwhile down-milling operation produced discontinuous type of chips.
    01/2014; 66(3). DOI:10.11113/jt.v66.2687
    • "Mechanisms of tool wear when machining nickel-base superalloys were reported in various publications [8,22,34,37,41,54–59]. However, most of the work is focused on turning and milling where tool flank wear, edge chipping, plastic deformation [8] [22] [37] [56] [58] and adhesion of work-piece material on the rake face [34] were the dominant failure modes. Attritional wear and thermal cracking at high cutting temperatures were also found to be responsible for tool fractures [57]. "
    [Show abstract] [Hide abstract]
    ABSTRACT: The study focuses on the surface integrity and wear mechanisms associated with mechanical micro-drilling of nickel-base superalloy (Inconel 718) under dry and wet cutting conditions. Mechanical and metallurgical characterization was undertaken using scanning electron microscopy (SEM), backscatter electron microscopy (BSE), electron backscatter diffraction microscopy (EBSD), transmission electron microscopy (TEM), focused ion beam (FIB) microscopy, nanoindentation, energy dispersive spectroscopy (EDS) and elemental analysis techniques. The surface integrity results revealed large scale near surface deformations with high dislocation density along with nanocrystalline grain structures both under wet cutting conditions, with evidence of recrystallisation and lower dislocation density for dry cutting. Cutting conditions play a significant role in determining the depth of the affected layer, the frequency of misorientations, the microstructures and the stored energy found there. The cutting temperature and use of coolant play a key role in the formation of the altered surfaces. Abrasion, diffusion and micro-chipping were found to be the main wear mechanisms for wet cutting compared to abrasion, high adhesion, macro-chipping and catastrophic failure for dry cutting. Adhesion of work-piece material to the tool associated with abrasion and diffusion processes is the main contributor to wear phenomena. The results are important in guiding the choice of cutting conditions for acceptable surface integrity.
    International Journal of Machine Tools and Manufacture 01/2014; 76:49–60. DOI:10.1016/j.ijmachtools.2013.10.002 · 3.04 Impact Factor
  • Source
    • "Based on the previous studies, the typical wear mechanism observed at the milling end of Inconel 718 with the ball nose tool is the localized flank wear, VB 3 . This is the maximum flank wear located near the depth of the cut line and is known as the depth of cut notching (Dudzinski et al. 2004; Krain et al. 2007; Li et al. 2006). Aspinwall et al. (2007) found that the radial depth of cut of more than 2 mm will affect the nature of wear that is dominated by the localized wear (notch wear) rather than the uniform flank wear. "
    [Show abstract] [Hide abstract]
    ABSTRACT: This paper presents the tool life of the end milled Inconel 718, which is part of a material that is difficult to be machined. Previous researchers found that tool life in machining aged Inconel 718 is shorter compared with other materials. However, this observation required further investigation. Thus, a raw grade Inconel was proposed in this experiment. The experiments were performed using TiAlN-coated carbide. The studied milling parameters were the cutting speed, Vc, from 90 to 150 m/min; feed rate, fz, from 0.15 to 0.25 mm/rev; depth of cut, ap, from 0.3 to 0.5 mm; and radial depth of cut, ae =1 mm. The application of the cutting fluid used in this experiment was a minimum quantity lubricant, which had the advantage of cooling effectiveness and low consumption of cutting fluid. The results showed that the feed rate, fz, was the primary factor controlling the tool life. The combination of Vc=115 m/min, fz=0.15 mm/tooth, as well as ap=0.5 mm and ae=0.15 mm gave the longest tool life that served 95.38 min in operation.
    Sains Malaysiana 12/2013; 42(12):1721-1726. · 0.45 Impact Factor
Show more