A state-of-the-art review on tool wear and surface integrity characteristics in machining of superalloys

Sarıkaya, Murat; Gupta, Munish Kumar; Tomaz, Ítalo; Pimenov, Danil Yurievich; Kuntoğlu, Mustafa; Khanna, Navneet; Yıldırım, Çağrı Vakkas; Królczyk, Grzegorz M.

doi:10.1016/j.cirpj.2021.08.005

Cited by 145 publications

(45 citation statements)

References 197 publications

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“…It can be found that increasing the uncut chip thickness can contribute to the formation of the hardened layer. The same trend was also concluded in a citable work [25]. The maximum microhardness on the machined surface does not exhibit significant difference.…”

Section: Microhardness Under the Machined Surfacesupporting

confidence: 81%

Machining-Induced Work Hardening Behavior of Inconel 718 Considering Edge Geometries

et al. 2022

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As a representative type of superalloy, Inconel 718 is widely employed in aerospace, marine and nuclear industries. The significant work hardening behavior of Inconel 718 can improve the service performance of components; nevertheless, it cause extreme difficulty in machining. This paper aims to investigate the influence of chamfered edge parameters on work hardening in orthogonal cutting of Inconel 718 based on a novel hybrid method, which integrates Coupled Eulerian-Lagrangian (CEL) method and grain-size-based functions considering the influence of grain size on microhardness. Orthogonal cutting experiments and nanoindentation tests are conducted to validate the effectiveness of the proposed method. The predicted results are highly consistent with the experimental results. The depth of work hardening layer increases with increasing chamfer angle and chamfer width, also with increasing feed rate (the uncut chip thickness). However, the maximum microhardness on the machined surface does not exhibit a significant difference. The proposed method can provide theoretical guidance for the optimization of cutting parameters and improvement of the work hardening.

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Section: Microhardness Under the Machined Surfacesupporting

confidence: 81%

Machining-Induced Work Hardening Behavior of Inconel 718 Considering Edge Geometries

et al. 2022

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“…The surface roughness of titanium alloys for both medical and other industries depends on the type and conditions of the treatment it is subjected to [12]. Although titanium alloy Ti6Al4V shows very good mechanical properties and is a widely known material used in industry, it belongs to the group of materials that are difficult to process [13,14]. Due to its properties, high temperature is generated within the cutting zone during machining and adversely affects the quality of the processed surface [15,16].…”

Section: Introductionmentioning

confidence: 99%

Corrosion Resistance and Surface Bioactivity of Ti6Al4V Alloy after Finish Turning under Ecological Cutting Conditions

et al. 2021

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The influence of cooling conditions and surface topography after finish turning of Ti6Al4V titanium alloy on corrosion resistance and surface bioactivity was analyzed. The samples were machined under dry and minimum quantity lubrication (MQL) conditions to obtain different surface roughness. The surface topographies of the processed samples were assessed and measured using an optical profilometer. The produced samples were subjected to electrochemical impedance spectroscopy (EIS) and corrosion potential tests (Ecorr) in the presence of simulated body fluid (SBF). The surface bioactivity of the samples was assessed on the basis of images from scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analysis. The inspection of the surfaces of samples after turning under dry and MQL conditions revealed unevenly distributed precipitation of hydroxyapatite compounds (Ca/P) with a molar ratio in the range of 1.73–1.97. Regardless of the cutting conditions and surface roughness, the highest values of Ecorr ~0 mV were recorded on day 7 of immersion in the SBF solution. The impedance characteristics showed that, compared to the MQL conditions, surfaces machined under dry conditions were characterized by greater resistance and the presence of a passive layer on the processed surface. The main novelty of the paper is the study of the effect of ecological machining conditions, namely, dry and MQL cutting on the corrosion resistance and surface bioactivity of Ti6Al4V titanium alloy after finish turning. The obtained research results have practical significance. They can be used by engineers during the development of technological processes for medical devices made of Ti6Al4V alloy to obtain favorable functional properties of these devices.

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“…According to the work of Dudzinski et al [4] and Wolf et al [5], the low thermal conductivity of Inconel 718 induces a concentration of heat in the cutting zone. The coupling of this phenomenon with the significant hardening of Inconel 718 for high temperatures leads to increased friction with the tool as reported by Sarikaya et al [6]. Moreover, the high nickel content of this superalloy frequently induces chip adhesion on the tool.…”

Section: Introductionmentioning

confidence: 65%

Study of the Thermal History upon Residual Stresses during the Dry Drilling of Inconel 718

Chenegrin

Bouscaud

Girinon

et al. 2022

Metals

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The main objective of this article was to show for the first time that heat transfer plays a major role in residual stress generation during the dry drilling of Inconel 718, and to propose a numerical strategy capable of simulating such thermo-mechanical phenomena. An X-ray diffraction (XRD) analysis shows that without lubrication, high tensile residual stresses can be observed on the surface of a deep through drilled hole. Such a situation can be highly detrimental for the fatigue lifetime of a mechanical component. A thermal history in five phases is first identified by means of temperature measurements exhibiting an overheating of approximately 500 ∘C on the created hole surface just before the end of the drilling operation. A 3D thermo-viscoplastic model is herein improved in terms of boundary conditions to show that this phenomenon is triggered by the progressive decrease in the Inconel 718 volume under the cutting zone. To the authors’ knowledge, such a phenomenon has never been reported and simulated before in the literature. Then, a 3D thermo-elasto-plastic simulation including elasticity is proposed to compute residual stresses from the thermal results of the previous model. It shows for the first time that the overheating stage induces sufficiently intense plasticity to produce high tensile residual stresses of approximately 900 MPa as we experimentally observed.

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A state-of-the-art review on tool wear and surface integrity characteristics in machining of superalloys

Cited by 145 publications

References 197 publications

Machining-Induced Work Hardening Behavior of Inconel 718 Considering Edge Geometries

Machining-Induced Work Hardening Behavior of Inconel 718 Considering Edge Geometries

Corrosion Resistance and Surface Bioactivity of Ti6Al4V Alloy after Finish Turning under Ecological Cutting Conditions

Study of the Thermal History upon Residual Stresses during the Dry Drilling of Inconel 718

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