A comparison between whisker-reinforced alumina and SiAlON ceramic tools in high-speed face milling of Inconel 718

Abstract

This study makes a comparison between whisker-reinforced alumina and SiAlON ceramic tools in high-speed face milling of Inconel 718. A series of tests have been conducted, and the cutting forces, tool wear morphologies and tool failure mechanisms are discussed with regard to a wide range of cutting speeds (500-3000 m/min). Results show that the resultant cutting force of SiAlON ceramic tool KY1540 is much bigger than that of whisker-reinforced alumina ceramic tool KY4300 at the same cutting condition. For both kinds of tools, under relatively lower cutting speed, nose notch wear is the predominant failure mode affecting the tool life, while further increase in the cutting speed, notch wear at the depth of cut becomes the determining factor. KY1540 shows a better notch wear and thermal shock resistance than KY4300. The tool failure mechanisms involve notching, microcracks, chipping, flaking, adhesion and oxidation wear. Better surface quality can be got using KY4300 ceramic tools.

Influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface

“…4–8 High-speed machining, which possesses high material removal rate and low cutting force, provides an efficient approach for machining Inconel 718 with high quality and high efficiency. 9–11 However, for high-speed machining of Inconel 718 curved surface, the geometrical characteristics are changing continuously leading to a sharp fluctuation of cutting force, which will aggravate the tool wear. In this way, it is of vital importance to study the tool wear in high-speed milling of Inconel 718 curved surface.…”

Micro-milling of unreinforced and reinforced polypropylene

“…The increase in spindle speed induced increase in the strain hardening of workpiece, thus the deformation resistance of shear area increased, which induced increment in the force. 43 The increment in the cutting force with spindle speed was also declared 44,45 by the increment friction between the micro end mill and workpiece with spindle speed. 44 The increase in the forces with spindle speed and feed rate was also reported in the literature studying micro-milling of unreinforced and glass fiber-reinforced polymer composite.…”

“…43 The increment in the cutting force with spindle speed was also declared 44,45 by the increment friction between the micro end mill and workpiece with spindle speed. 44 The increase in the forces with spindle speed and feed rate was also reported in the literature studying micro-milling of unreinforced and glass fiber-reinforced polymer composite. 6 In general, maximum P-to-V Fx and Fy values were higher for PP-GF composite than those for PP polymer.…”

Effect of cutting speed on chip formation and wear mechanisms of coated carbide tools when ultra-high-speed face milling titanium alloy Ti-6Al-4V

“…To obtain higher cutting speed during traditional machining, a larger tool diameter of the end mill is usually applied in the high-speed machining tests. [18][19][20][21][22] Li et al 23,24 had tried to use PCD in high-and very high-cutting speed (500-2000 m/min) milling of titanium alloy with a large diameter (125 mm) face mill equipped with the cutting width of one-fifth dimension of the tool diameter. The increase in cutting speed dramatically decreases tool life.…”