Comparison between Up-milling and Down-milling Operations on Tool Wear in Milling Inconel 718

Hadi, Musfirah Abdul; Ghani, Jaharah A; Haron, Che Hassan Che; Kasim, Mohd Shahir

doi:10.1016/j.proeng.2013.12.234

Cited by 43 publications

(34 citation statements)

References 14 publications

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“…The transient temperature of the machined surface is relatively high which gives rise to thermal stress [52]. This configuration is generally the best way to machine parts today since it reduces the load from the cutting edge, leaves a better surface finish (chips are removed behind the cutter) and also improves tool life [7].…”

Section: Surface Integrity (I) Down-milled Surface Integritymentioning

confidence: 99%

“…It is well established that the cutting forces and thermal gradients generated by the up-milling and down-milling modes during the contact tool-material are not identical [2,3]. Consequently, the machined surface integrity (including surface roughness, micro-structural changes, residual stresses and sometimes damaging defects) is certainly different [4][5][6] as well as the tool wear rate [7][8][9] and also the dynamic stability of milling process [10].…”

Section: Introductionmentioning

confidence: 99%

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Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Laamouri

Ghanem

Braham

et al. 2019

Int J Adv Manuf Technol

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. This is an author-deposited version published in: https://sam.ensam.eu Handle ID: .http://hdl.handle.net/10985/18458 To cite this version :Adnen LAAMOURI, Farhat GHANEM, Chedly BRAHAM, Habib SIDHOM -Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel Abstract This paper aims to compare the influences of the two peripheral milling modes, up-milling and down-milling, on surface integrity and fatigue strength of X160CrMoV12 high-alloy steel. The experimental investigations showed an important difference between integrity of both milled surfaces. The down-milled surface is lowly work-hardened and well finished (lower roughness), but subjected to tensile residual stresses and severely damaged by folds of metal and short micro-cracks. The up-milled surface is highly work-hardened and subjected to compressive residual stresses, but poorly finished (higher roughness) and damaged by a density of micro-cavities due to carbide extraction. The results of 3-point bending fatigue tests revealed that the fatigue limit at 2 × 10 6 cycles of the up-milled state is largely higher of about 26% in comparison with the down-milled state. The effects of surface integrity induced by each milling mode on fatigue strength were evaluated using a HCF behaviour predictive approach based on Dang Van's multiaxial criterion. The predictive results estimated that the pre-existing micro-cracks play a dominant role in the fatigue strength degradation of the down-milled surface while the other surface effects seem to be lower. On the contrary, the fatigue strength of the up-milled surface is less affected by the pre-existing micro-cavities. The detrimental roughness effect (stress concentration effect) is significantly reduced by the beneficial effects of superficial hardening and compressive residual stresses. So, this study revealed that up-milling is the more appropriate mode for a better surface integrity towards fatigue strength of X160CrMoV12 steel than the down-milling mode.

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Section: Surface Integrity (I) Down-milled Surface Integritymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Laamouri

Ghanem

Braham

et al. 2019

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…This rubbing of the tool against the workpiece causes excessive adhesive tool wear during up-milling operation. Also, the rubbing in the beginning of cut causes an excessive work hardening layer on the newly exposed surface of the workpiece (Hadi et al, 2013). During rotation of tool, the next tool flute penetrates into the work hardened layer created by previous rotation of the tooth, further exacerbates the tool wear.…”

Section: °mentioning

confidence: 99%

“…Due to maximum thickness of the chip in the beginning of tool penetration into workpiece, tearing did not initiate at all. A continuous strip of chip called segmented chip with a typical saw-tooth shape (Hadi et al, 2013) is obtained in emulsion up-milling after each pass as shown in Figure 16 for passes 1, 5 and 8. The vertical cross-sections shown in Figure 16(a) of the lamella are due to saw tooth shape of the chip.…”

Section: Chip Morphologymentioning

confidence: 99%

“…Zhu et al (2016) investigated the mechanism under which the degree of segmentation of chip becomes more and more with progression of tool wear in the end-milling of Ti-6Al-4V. Hadi et al (2013) reported improvement in tool wear using down-milling operation than up-milling in ball nose end-milling of Inconel 718 using MQL. They reported that the tool wear increased with increase in depth of cut, feed-rate and cutting speed.…”

Section: Introductionmentioning

confidence: 99%

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Effects of Milling Methods and Cooling Strategies on Tool Wear, Chip Morphology and Surface Roughness in High Speed End-Milling of Inconel-718

Jasra

Okafor

2019

IJMMM

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This paper presents the results of experimental investigation of the effects of milling methods (up-milling and down-milling) and cooling strategies [emulsion cooling, minimum quantity lubrication (MQL), cryogenic cooling using liquid nitrogen (LN 2) and combined (MQL + LN 2)] on flank wear, chip morphology and surface roughness in peripheral high speed end-milling of Inconel-718. The experimental results show that down-milling generated lower maximum flank wear than up-milling for all cooling strategies, thus improves machinability. MQL cooling with down-milling generated lowest maximum flank wear of 0.072 mm after eight passes and is recommended for machining Inconel-718, whereas LN 2 cooling with up-milling generated highest flank wear of 1.984 mm after first pass only. Tool wear mechanism in up-milling is adhesion and failure modes are chipping and plastic deformation, causing rapid tool wear, while abrasion is the tool wear mechanism under down-milling causing progressive tool wear. Also, emulsion up-milling generated lowest surface roughness of 0.29 μm, whereas emulsion, MQL and combined (MQL + LN 2) cooling strategies with down-milling generated equal and second lowest surface roughness of 0.34 μm. Results show that using MQL cooling under down-milling for machining Inconel-718 can lead to significant cost saving and sustainable machining.

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Cutting Performance and Wear Mechanism of Multilayer Diamond‐Coated Tools

et al. 2023

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Monolayer and multilayer diamond films are deposited on WC‐Co cemented carbide by hot‐filament chemical vapor deposition. The growth characteristics of diamond coatings are analyzed. Cutting performance characteristics such as tool life and the stability of machining process in the machining of presintered ZrO2 are compared based on the variation of cutting speed and resultant cutting force, and workpiece surface roughness. For the monolayer diamond coatings, as the concentration of CH4 increases from 1% to 5%, the diamond crystal is transformed from micron columnar crystal to nanocluster crystal. The multilayer diamond coatings combine the advantages of micron‐ and nanocrystalline structures. The multilayer diamond‐coated tool exhibits longer service life and better machining quality. Because of the appearance of the brittle–plastic conversion mechanism, the surface integrity of ZrO2 processed by multilayer diamond‐coated tool is relatively high. As for the uncoated tool, the workpiece is mainly machined by brittle spalling. The interfacial stratified fracture system between the interlayers is proposed to be the toughening mechanism of the multilayer structure.

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Comparison between Up-milling and Down-milling Operations on Tool Wear in Milling Inconel 718

Cited by 43 publications

References 14 publications

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Effects of Milling Methods and Cooling Strategies on Tool Wear, Chip Morphology and Surface Roughness in High Speed End-Milling of Inconel-718

Cutting Performance and Wear Mechanism of Multilayer Diamond‐Coated Tools

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