Adhesion of Inconel 718 on Uncoated Tungsten Carbide Inserts in Interrupted Orthogonal Machining under MQL

Alammari, Youssef; Iovkov, Ivan; Saelzer, Jannis; Wolf, Tobias; Biermann, Dirk

doi:10.1016/j.procir.2021.10.031

Cited by 4 publications

(2 citation statements)

References 27 publications

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“…Recent contributions to the literature [2,3] have explored sustainable machining methods across various materials and processes. The observed low tool-chip contact in the initial period of chip formation (IPCF), where reduced tool-chip friction is observed at the beginning of cutting [4], indicates promising potential for sustainable machining. Figure 1 illustrates the main characteristics of IPCF chips: small chip thickness, large shear angle, minimal secondary shear zone, and small chip curl radius.…”

Section: Introductionmentioning

confidence: 99%

Transient Temperature at Tool–Chip Interface during Initial Period of Chip Formation in Orthogonal Cutting of Inconel 718

Alammari,

Weng,

Saelzer

et al. 2024

Materials

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Machining nickel-based super alloys such as Inconel 718 generates a high thermal load induced via friction and plastic deformation, causing these alloys to be among most difficult-to-cut materials. Localized heat generation occurring in machining induces high temperature gradients. Experimental techniques for determining cutting tool temperature are challenging due to the small dimensions of the heat source and the chips produced, making it difficult to observe the tool–chip interface. Therefore, theoretical analysis of cutting temperatures is crucial for understanding heat generation and temperature distribution during cutting operations. Periodic heating and cooling occurring during cutting and interruption, respectively, are modeled using a hybrid analytical and finite element (FE) transient thermal model. In addition to identifying a transition distance associated with initial period of chip formation (IPCF) from apparent coefficient of friction results using a sigmoid function, the transition temperature is also identified using the thermal model. The model is validated experimentally by measuring the tool–chip interface temperature using a two-color pyrometer at a specific cutting distance. Due to the cyclic behavior in interrupted cutting, where a steady-state condition may or may not be achieved, transient thermal modeling is required in this case. Input parameters required to identify the heat flux for the transient thermal model are obtained experimentally and the definitions of heat-flux-reducing factors along the cutting path are associated with interruptions and the repeating IPCF. The thermal model consists of two main parts: one is related to identifying the heat flux, and the other part involves the determination of the temperature field within the tool using a partial differential equation (PDE) solved numerically via a 2D finite element method.

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Section: Introductionmentioning

confidence: 99%

Transient Temperature at Tool–Chip Interface during Initial Period of Chip Formation in Orthogonal Cutting of Inconel 718

Alammari,

Weng,

Saelzer

et al. 2024

Materials

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“…It has been observed that interrupted machining can enhance the machinability of low thermal conductivity materials such as stainless steels, titanium or nickel-base alloys (e.g. Inconel 718) [7,8]. These difficult-to-cut materials require relatively low cutting speeds to avoid high temperatures caused by poor heat dissipation out of the tool-chip interface that is rather carried away with the removed chips.…”

Section: Introductionmentioning

confidence: 99%

Initial Period of Chip Formation: Observations Towards Enhancing Machining Sustainability

Alammari

Saelzer

Berger

et al. 2023

Lecture Notes in Mechanical Engineering

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In machining, high mechanical and thermal loads are exerted on a small area of the tool where it interacts with the workpiece. Despite limited interaction space, extensive use of cutting fluids (CFs) is inefficiently used to improve the machining process and increase productivity. In order to minimize CFs’ negative impact on health, environment and financial burden, various strategies have been developed and studied to optimize their use including minimum quantity lubrication. In this research, initial period of chip formation (IPCF), that occurs during a narrow window of space and time at the beginning of the cut, is closely investigated in an orthogonal machining setup. During IPCF, low mechanical loads were observed. The existence of IPCF is further investigated under interrupted cutting process at prescribed intervals in order to sustain its positive effects. In addition, 2D numerical chip formation friction model is proposed. The numerical model comprises a friction criterion dependent on tool temperature that is observed to be associated with a transient friction regime.

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The influence of cutting edge microgeometry on the broaching of Inconel 718 slots

Fabián Pérez-Salinas,

Fernández-Lucio,

del Olmo

et al. 2023

Engineering Science and Technology, an International Journal

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Adhesion of Inconel 718 on Uncoated Tungsten Carbide Inserts in Interrupted Orthogonal Machining under MQL

Cited by 4 publications

References 27 publications

Transient Temperature at Tool–Chip Interface during Initial Period of Chip Formation in Orthogonal Cutting of Inconel 718

Transient Temperature at Tool–Chip Interface during Initial Period of Chip Formation in Orthogonal Cutting of Inconel 718

Initial Period of Chip Formation: Observations Towards Enhancing Machining Sustainability

The influence of cutting edge microgeometry on the broaching of Inconel 718 slots

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