Laser-Assisted Milling of Silicon Nitride Ceramics and Inconel 718

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Yinggang Tian ◽  
Benxin Wu ◽  
Mark Anderson ◽  
Yung C. Shin
Keyword(s):  
Silicon Nitride ◽  
Inconel 718 ◽  
Thermal Model ◽  
Cutting Tools ◽  
Three Dimensional ◽  
Infrared Camera ◽  
Advanced Materials ◽  
Good Surface ◽  
Nitride Ceramics ◽  
Coated Carbide

Laser-assisted machining (LAM) has shown its potential to significantly reduce fabrication costs and improve product quality for advanced materials. While extensive studies have been conducted on laser-assisted turning of various ceramics and high temperature alloys, few attempts have been made to extend LAM to milling operations. In this paper, a transient, three-dimensional thermal model developed for laser-assisted milling (LAML) is presented and its accuracy is verified by surface temperature measurements with an infrared camera. LAML experiments designed by the model are successfully conducted on silicon nitride ceramics using TiAlN coated carbide end mills and Inconel 718 using SiC reinforced alumina cutting tools. The promising experimental results, including good surface roughness and acceptable tool wear, show the validation of applying the thermal model to design LAML processes and the feasibility of employing LAML for difficult-to-machine materials such as advanced ceramics and superalloys.

Laser-Assisted Milling of Silicon Nitride Ceramics

2006 ◽  
Author(s):  
Yinggang Tian ◽  
Benxin Wu ◽  
Yung C. Shin
Keyword(s):  
Silicon Nitride ◽  
Thermal Model ◽  
Three Dimensional ◽  
Infrared Camera ◽  
Ceramic Materials ◽  
Good Surface ◽  
Milling Operations ◽  
Nitride Ceramics ◽  
Good Surface Roughness ◽  
Coated Carbide

Laser-assisted machining (LAM) has shown its potential to significantly reduce fabrication costs and improve product quality for advanced ceramic materials. While extensive studies have been conducted on laser-assisted turning (LAT) of various ceramics, few attempts have been made to extend LAM to milling operations. In this paper, a transient, three-dimensional thermal model is developed for laser-assisted milling (LAML) and verified by surface temperature measurements with an infrared camera. LAML experiments designed by the model are successfully conducted on silicon nitride ceramics using TiAIN coated carbide end mills. The promising experimental results, including good surface roughness and acceptable tool wear, show the validation of applying the thermal model to design LAML processes and the feasibility of employing LAML to advanced ceramics.

Thermal Modeling for Laser-Assisted Machining of Silicon Nitride Ceramics with Complex Features

2005 ◽  
Vol 128 (2) ◽  
pp. 425-434 ◽  
Author(s):  
Yinggang Tian ◽  
Yung C. Shin
Keyword(s):  
Silicon Nitride ◽  
Thermal Model ◽  
Three Dimensional ◽  
Infrared Camera ◽  
Ceramic Materials ◽  
Industrial Applications ◽  
Laser Assisted Machining ◽  
Nitride Ceramics ◽  
Complex Features ◽  
Fabrication Costs

The feasibility of laser-assisted machining (LAM) and its potential to significantly reduce fabrication costs and improve product quality have been shown experimentally for various ceramic materials. However, no systematical investigation has been performed to expand LAMs capability to parts with complex features, although such capability is essential for industrial applications. This paper presents a transient, three-dimensional thermal model developed for LAM of workpieces with complex geometric features and its validation by in-process surface temperature measurements with an infrared camera. It is shown that the LAM experiments designed based on the predictions by the thermal model successfully produced silicon nitride parts with complex features, thus demonstrating the capabilities of LAM in fabricating ceramic parts suitable for industrial implementation.

Tool Wear Behavior in Turning Inconel 718 with Coated Inserts

2012 ◽  
Vol 499 ◽  
pp. 348-352 ◽  
Author(s):  
Xiao Li Zhu ◽  
Song Zhang ◽  
X.L. Xu ◽  
H.G. Lv
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Flank Wear ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Three Dimensional ◽  
Cutting Condition ◽  
Tool Holder ◽  
Final Failure ◽  
Coated Carbide

In the present study, an experimental investigation has been carried out in an attempt to monitor tool wear progress in turning Inconel 718 with coated carbide inserts under the wet cutting condition. First, each experimental test was conducted with a new cutting edge and the turning process was stopped at a certain interval of time. Secondly, the indexable insert was removed from the tool holder and the flank wear of the insert was measured using a three-dimensional digital microscopy (VHX-600E); and then the insert was clamped into the tool holder for the next turning experiment. The final failure of tool wear surfaces were examined under a scanning electron microscope (SEM) equipped with an energy dispersive X-ray spectrometer (EDS). It is indicated that significant flank wear was the predominant failure mode, and the abrasive, adhesive and oxidation wear were the most dominant wear mechanisms which directly control the deterioration and final failure of the cutting tools.

Development of High Performance Silicon Nitride Ceramics and their Applications

1992 ◽  
Vol 287 ◽  
Author(s):  
Yo Tajima
Keyword(s):  
Mechanical Properties ◽  
Silicon Nitride ◽  
High Performance ◽  
Future Prospect ◽  
Cutting Tools ◽  
Sintering Process ◽  
Sintering Additives ◽  
Nitride Ceramics ◽  
Engine Components

ABSTRACTProgress in sintering process and improvement of mechanical properties of silicon nitride ceramics are reviewed. Emphases are placed on contributions of advanced sintering techniques and better understanding of sintering additives and microstructure-properties relations. Current applications as engine components and cutting tools are described, and future prospect is considered.

Studies on the application of hot-pressed silicon nitride ceramics as cutting-tools

1980 ◽  
Vol 6 (1) ◽  
pp. 36-39 ◽  
Author(s):  
Miao Ho-Cho ◽  
Chow Chia-Bao ◽  
Liu Yuan-Ho ◽  
Chiang Tso-Chao ◽  
Liu Kuo-Liang ◽  
...  
Keyword(s):  
Silicon Nitride ◽  
Cutting Tools ◽  
Nitride Ceramics

Wear Behavior of Multilayer Nanocomposite TiAlSiN/TiSiN/TiAlN Coated Carbide Cutting Tool during Face Milling of Inconel 718 Superalloy

2017 ◽  
Vol 47 ◽  
pp. 11-16 ◽  
Author(s):  
Bilal Kursuncu ◽  
Halil Caliskan ◽  
Sevki Yilmaz Guven ◽  
Peter Panjan
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Elevated Temperatures ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Face Milling ◽  
Carbide Cutting Tool ◽  
Inconel 718 Superalloy ◽  
Coated Carbide

The Inconel 718 superalloy is one of the most-used nickel based superalloys in the aerospace industry due to its superior mechanical properties, for instance, high thermal and chemical resistance, and high strength at elevated temperatures. However, the work hardening tendency, low thermal conductivity and high hardness of this superalloy cause early tool wear, leading to the material to be called as a hard-to-cut material. Therefore, deposition of a wear resistant hard coating on carbide cutting tools has a critical importance for longer tool life in milling operations of the Inconel 718 superalloy. In this study, carbide cutting tools were coated with multilayer nanocomposite TiAlSiN/TiSiN/TiAlN coating using the magnetron sputtering technique, and wear behavior of the coated tool was investigated during face milling of the Inconel 718 superalloy under dry conditions. Abrasive and adhesive wear mechanisms were founded as main failure mechanisms. The nanocomposite TiAlSiN/TiSiN/TiAlN coated carbide cutting tool gave better wear resistance, and thus it provided 1.7 times longer tool life and a smoother surface (Ra<0.18 μm) on the Inconel 718 material than the uncoated one.

Influence of the Coated Carbide Grade on the Cutting Tool Life When Machining Inconel 718

2016 ◽  
Vol 674 ◽  
pp. 271-276
Author(s):  
Tomáš Bakša ◽  
Michal Morávek ◽  
Miroslav Zetek
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
High Heat ◽  
Nuclear Industry ◽  
Inconel 718 Alloy ◽  
The Right ◽  
Coated Carbide ◽  
Milling Tools

This article deals with the machining of Inconel 718 alloy. In the research, several carbide milling tools with different carbide grades and coatings were used. The main aim is compare all cutting tools in terms of their cutting tool life during machining super alloy Inconel 718. This material is used for highly stressed components in the nuclear industry, such as combustion turbine. Due to its rapid hardening and high heat generation, it is very problematic to machining. The right choice of appropriate carbide grade is necessary to achieve high-quality cutting wedge, which is important for good adhesion of the coating. The results of this work will be used for further research and development of cutting tools for machining Inconel 718.

Experimental Study on Laser Assisted Milling of Sintered Silicon Nitride Ceramics

2011 ◽  
Vol 121-126 ◽  
pp. 830-834
Author(s):  
Xiang Wei Wang ◽  
Hong Zhi Zhang ◽  
Xue Feng Wu ◽  
Yang Wang ◽  
Li Jun Yan
Keyword(s):  
Silicon Nitride ◽  
Material Removal ◽  
Chip Morphology ◽  
Experimental System ◽  
Potential Method ◽  
Power Laser ◽  
Good Surface ◽  
Nitride Ceramics ◽  
Set Up ◽  
Sintered Silicon

Laser assisted milling (LAML) is a potential method for machining difficult-to-machine materials such as superalloys and ceramics, which uses a high power laser to focally heat a workpiece prior to material removal with a traditional cutting tool. A laser assisted milling experimental system was set up to investigate the cutting process of LAML of sintered silicon nitride. Effects of operating parameters on cutting forces, chip morphology, surface roughness and subsurface damage were investigated. The results showed the feasibility and advantages of LAML of ceramics including good surface, decreasing cutting force and tool wear, and no micro-crack zones.

Tool wear appearance and failure mechanism of coated carbide tools in micro-milling of Inconel 718 super alloy

2016 ◽  
Vol 68 (2) ◽  
pp. 267-277 ◽  
Author(s):  
Xiaohong Lu ◽  
Zhenyuan Jia ◽  
Hua Wang ◽  
Likun Si ◽  
Yongyun Liu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Failure Mechanism ◽  
Inconel 718 ◽  
High Efficiency ◽  
Cutting Tools ◽  
Milling Process ◽  
Micro Milling ◽  
Content Type ◽  
Diffusion Wear ◽  
Coated Carbide

Purpose – The paper aims to study the wear and breakage characteristics of coated carbide cutting tools through micro-milling slot experiments on superalloy Inconel 718. Design/methodology/approach – During the micro-milling process, the wear and breakage appearance on the rake face and flank face of the cutting tools, as well as the failure mechanism, have been studied. Furthermore, the wear and breakage characteristics of the micro-cutting tools have been compared with the traditional milling on Inconel 718. Findings – The main failure forms of the micro tool when micro-milling Inconel 718 were tool tip breakage and coating shed on the rake and flank faces of the cutting tool and micro-crack blade. The main causes of tool wear were synthetic action of adhesive abrasion, diffusion wear and oxidation wear, while the causes of abrasive wear were not obvious. Practical implications – The changing trend in tool wear during the micro-milling process and the main reasons of the tool wear are studied. The findings will facilitate slowing down the tool wear and prolonging the tool life during micro-milling Inconel718. Originality/value – The results of this paper can help slow down the tool wear and realize high efficiency, high precision and economical processing of small workpiece or structure of the nickel-based superalloy.

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