In this study, high speed milling of stainless steel was tried for purpose of high efficiency cutting of a steam turbine blade. In the experiment, cutting tool used TiAlN coating radius solid end mill made of cemented carbide. Diameter of end mill is 5mm. Corner radius is 0.2mm. Cutting speed carried out at 100m/s~600m/s. Work pieces was used in the experiment are four kinds of stainless steel which alloy elements differ. Mainly, content of chromium and nickel is different. There are many researches about high speed milling [1, 2].However, the researches which examined relationship between alloy elements of stainless steel and cutting characteristics on high speed milling using small diameter endmill are few.As the results, in the case of stainless steel containing much nickel, tool life becomes short in high speed cutting area. This reason is nickel has low thermal conductivity. Because the cutting point temperature becomes higher. If the coating removes, wear becomes large rapidly. In other words, maximum limit value of cutting speed was found to be dependent on heat resistance temperature of the coating.On the other hand, Chromium has the effect of improving the abrasion resistant of the workpiece. However, Flank wear was not increased in a low cutting speed area. In the range of this experimental condition, chromium didn't influence tool life. When cutting point temperature is below heat resistant temperature of the coating, it is thought that effect of the coating is maintained. Namely, it was found that appropriate cutting speed followed heat resistant temperature of the coating.
Stainless steel is an excellent material that has properties such as heat and corrosion resistance. Thus, stainless steel is used as a material in steam turbine blades. Steam turbine blades are mainly manufactured using two methods. One is the cutting of unforged metal ingots. Another is the cutting of forged parts. Small blades are made by cutting metal ingots. Large blades are made by cutting forged parts. The mechanical characteristics of a metal ingot and a forged part, such as hardness and toughness, are almost the same. There were not researches related to a relationship between “an unforged ingot and a forged part of stainless steel” and “the differences of the tool wear and the finished surface by high-speed milling”.In this study, the high-speed milling of stainless steel was attempted for high-efficiency cutting of a steam turbine blade. The differences of the tool wear and the finished surface in the cuttings of an unforged ingot and a forged part were investigated. In the experiment, the cutting tool was a TiAlN coating radius solid end mill made of cemented carbide. The diameter of the end mill was 5 mm, and the corner radius was 0.2 mm. The cutting speed were 100 m/min-600 m/min. The workpieces used were a metal ingot and a forged part of stainless steel. In the results, it was found that the differences of the tool wear and the finished surface in the cuttings of an unforged ingot and a forged part. In the case of the unforged ingot, the flank wear became large with increasing cutting speed. On the other hand, in the case of forged part, the flank wear rapidly increased at a cutting speed of 100 m/min. In addition, the flank wear became smaller than the cutting speed 100 m/min at the cutting speed 200 m/min. Further, the flank wear became large with increasing cutting speed at cutting speeds higher than 200 m/min. That is, the flank wear was at a minimum at a cutting speed of 200 m/min. Although it could not be confirmed the characteristic of high speed milling at an unforged ingot, it has been identified at a forged part.
A titanium alloy and stainless steel is an excellent material having properties such as high intensity and high corrosion resistance. Therefore, a titanium alloy and a stainless steel are used as material of steam turbine blade. However, the machining efficiency of a titanium alloy and a stainless steel is a low because of difficult-to-cut materials. Especially, it is a major problem that the cutting point temperature is high and the tool life is short. In the conventional study, it is reported that the cutting point temperature is low and the tool life becomes long by cutting at the suitable cutting speed corresponding to material characteristics. This concept is known as high speed milling. In recent years, the high speed milling is actually used for the metal mold machining. In this study, the high speed milling of the titanium alloy and the stainless steel was tried for the purpose of high efficiency cutting of a steam turbine blade. In the experiment, the cutting tool used the TiAlN coating radius solid end mill made of micro grain cemented carbide. The diameter of endmill is 5mm. The corner radius is 0.2mm. And, the work piece is the titanium alloy Ti-6Al-4V and stainless steel 13Cr. The cutting speed carried out at 100m/min~600m/min. As the result, when the tool life and the surface roughness was a valuation basis, the optimum cutting speed of titanium alloy was 300m/min. On the other hand, In the case of the stainless steel, the flank wear becomes large in proportion to cutting speed. The feature of high speed milling was not able to be confirmed in the range of this experimental condition.
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