Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool

Abstract

Understanding how feed rate (f t ) affects tool deterioration during milling of Ni-based superalloys is practically important, but this understanding is currently insufficient. In the present study using a 718Plus Ni-based alloy and cemented tungsten carbide tool inserts, milling experiments were conducted with f t = 0.10 mm/tooth under either dry or wet (with coolant) conditions. The results are compared to those based on using f t = 0.05 mm/tooth from previous studies. The milling force (F) was monitored, the cutting tool edge was examined and the flank wear (VB max ) was measured. As would be expected, an increase in f t increased F. It was found that F correlated well with VB max for the high f t (0.1 mm/tooth) experiments, as opposed to the previously observed poor F-VB max relationship for the lower f t (0.05 mm/tooth) value. This is explained, supported by detailed failure analysis of the cutting tool edges, by the deterioration mode to be dominantly edge chipping with a low occurrence of fracturing along the flank face when the high f t was used. This dominancy of the deterioration mode means that the tool edge and workpiece contact was consistent and thus resulted in a clear F-VB max relationship. A clear F-VB max relationship should then mean monitoring VB max through monitoring F is possible.

Modelling and Microstructural Aspects of Ultra-Thin Sheet Metal Bundle Cutting

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