Workpiece Surface Integrity and Tool Life Issues When Turning Inconel 718™ Nickel Based Superalloy

2004 ◽  
Vol 8 (3) ◽  
pp. 399-414 ◽  
Author(s):  
A. R. C. Sharman ◽  
J. I. Hughes ◽  
K. Ridgway
Keyword(s):  
Tool Life ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Workpiece Surface ◽  
Nickel Based Superalloy ◽  
Life Issues

Detecting the key geometrical features and grades of carbide inserts for the turning of nickel-based alloys concerning surface integrity

2016 ◽  
Vol 230 (20) ◽  
pp. 3725-3742 ◽  
Author(s):  
A Fernández-Valdivielso ◽  
LN López de Lacalle ◽  
G Urbikain ◽  
A Rodriguez
Keyword(s):  
Surface Integrity ◽  
Inconel 718 ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Rake Angle ◽  
Point Of View ◽  
Basic Operation ◽  
Workpiece Surface ◽  
Common Features ◽  
Feasible Solutions

Machining science is aimed at defining both cutting tools and machining conditions based on economic performance and to maintain workpiece surface integrity. Currently, machinists face a wide offer of turning, milling, drilling, and threading tools. Tools present a lot of similarities and light differences between them, being the latter the concealed reasons for a better or worse performance on difficult-to-cut alloys machining. However machinists had not useful methods for detecting which key tool aspects implies the best performance. The classic and expensive 'test-trial' method results non-viable due to the market exponential increase, both in size and specialization. This paper brings up an indirect method for seeking common features in the group of those tools with the best performance on machining Inconel 718. The method is divided into five stages, namely: (a) raw testing of a basic operation with a lot of commercial solutions for the same operation; (b) filtering of results to reduce the feasible solutions to a few ones, studying the common features of successful cases; (c) testing of these feasible solutions aimed at choosing the best insert or tool (d); and finally (e) full testing concerning all workpiece surface integrity issues. The proposed method provides knowledge based on the distilling of results, identifying carbide grades, chipbreakers shapes, and other features for having the best tool performance. All surface integrity effects are checked for the best solution. This new point of view is the only way for improving the difficult-to-cut alloys machining, reaching technical conclusions with industrial interest. This paper shows the method applied on Inconel 718 turning, resulting in a carbide grade with 10% cobalt, submicron grain size (0.5–0.8 µm) and hardness around 1760 HV, coating TiAlN monolayer with 3.5 µm thickness, chipbreaker giving 19° of rake angle that becomes 13° real one after insert is clamped on toolholder. Cutting edge radius after coating was 48 µm approximately. Cutting speed was 70 m/min higher in comparison with that recommended in handbooks.

scholarly journals An evaluation of the evolution of workpiece surface integrity in hole making operations for a nickel-based superalloy

2012 ◽  
Vol 212 (8) ◽  
pp. 1723-1730 ◽  
Author(s):  
C.R.J. Herbert ◽  
J. Kwong ◽  
M.C. Kong ◽  
D.A. Axinte ◽  
M.C. Hardy ◽  
...  
Keyword(s):  
Surface Integrity ◽  
Workpiece Surface ◽  
Nickel Based Superalloy ◽  
Hole Making

scholarly journals An experimental investigation on Inconel 718 interrupted cutting with ceramic solid end mills

2021 ◽  
Author(s):  
Paolo Parenti ◽  
Francesco Puglielli ◽  
Massimo Goletti ◽  
Massimiliano Annoni ◽  
Michele Monno
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Surface Integrity ◽  
Wear Mechanisms ◽  
Inconel 718 ◽  
Turbine Blades ◽  
Cutting Speed ◽  
Material Surface ◽  
End Mills ◽  
Signal Monitoring

AbstractSolid ceramic end mills for machining heat resistant super alloys (HRSA) have the potential to generate higher material removal rates, up to one order of magnitude, with respect to standard carbide tools. The machining operations in aerospace industry, where large removals are required to obtain tiny and slender parts like turbine blades, is a cost-intensive task that can benefit of the adoption of ceramic solid end mills. However, these tools show a quite limited tool life, especially when used with interrupted tool engagement strategies. Moreover, they might induce heat-related problems in the workpiece material surface integrity. This paper investigates the cutting and the tool wear during milling Inconel 718 with solid ø12 mm cutting end tool made by SiAlON. The wear mechanisms are studied together with their effects on process signals as cutting forces and power, measured via external and CNC integrated sensors. The carried experimental campaign allowed to find out that tool clogging and edge chipping were the primary cutting phenomena leading the tool wear. Cutting strategy (downmilling or upmilling) produced different results in terms of tool wear sensitivity and process outputs whereas upmilling configuration showed the best results in terms of cutting signals stability and surface integrity. At the same time, cutting speed was found to increase the cutting power more in upmilling than downmilling cutting. The analysis of the forces and power demonstrated that the typical tool wear mechanisms can be traced by signal monitoring due to their high impact on cutting processes. This fact shows the good potential of signal monitoring for a better tool life evaluation.

Tool Life and Surface Integrity When Machining Inconel 718 With PVD- and CVD-Coated Tools

1999 ◽  
Vol 42 (2) ◽  
pp. 353-360 ◽  
Author(s):  
E. O. Ezugwu ◽  
Z. M. Wang ◽  
C. I. Okeke
Keyword(s):  
Tool Life ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Coated Tools
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