High-pressure flank cooling and chip morphology in turning Alloy 718

Alagan, Nageswaran Tamil; Zeman, Pavel; Mára, Vladimír; Beňo, Tomáš; Wretland, Anders

doi:10.1016/j.cirpj.2021.08.012

Cited by 11 publications

(7 citation statements)

References 27 publications

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“…Metalworking fluids are used extensively in metalworking processes, such as forming, forging and machining [1][2][3]. In machining, cutting fluids (CFs) are essential to reduce tool wear and extend tool life and maintain the surface integrity of the part [4][5][6][7]. The finish machining of turbomachinery components used in aircraft engines is a critical last stage manufacturing process, and CFs are essential to maintain process capability.…”

Section: Introductionmentioning

confidence: 99%

“…Ni-based superalloys retain their high strength to 650 • C and display high resistance to oxidizing and corrosive environments [15]. As such, Inconel 718 alloy is difficult to machine, with tools displaying high rates of flank and crater wear, chipping and notching, a propensity for BUE and lower productivity compared to many other alloys [5][6][7]11,16]. In machining Inconel 718, wear is caused by the hard precipitate phases such as γ within the FCC-γ primary phase of the alloy that gradually abrades the tool's cutting edge [17].…”

Section: Introductionmentioning

confidence: 99%

“…Industrial machine tools must be stiff for machining highstrength superalloys [7]. Table 1 identifies important published works on turning Inconel 718 [5][6][7]11,15,[18][19][20][21][22][23][24][25][26][27] to improve production efficiencies and maintain surface integrity of the machined part by studying a wide range of process parameters, tool geometries and materials, with and without coatings, and coolant types. Of these, only few works [20,21,27] studied finish turning of Inconel 718, using a small tool nose radius of 0.4 mm and a small depth of cut (~0.25 mm) with coated and uncoated tools and an emulsion coolant, and none used a bio-easter emulsion coolant.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Long Sump Life Effects of a Naturally Aged Bio-Ester Oil Emulsion on Tool Wear in Finish Turning a Ni-Based Superalloy

Wood,

Mantle,

Boud

et al. 2023

Metals

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This paper discusses a method of finish turning Inconel 718 alloy to compare machining performance of a naturally aged and used metalworking fluid (MWF), which had been conventionally managed through its life cycle, with the same new unaged product. The MWF concentrate was a new-to-market bio-ester oil, diluted with water to produce an emulsion. In the experiments, 50 mm diameter bars were turned down with multiple passes at a 250 μm depth of cut to reach a tool flank wear of 200 μm. The machining was interrupted at several stages to measure the flank wear and compare the chip forms for the aged and unaged MWF. The method of finish turning used a small tool nose radius and a small depth of cut that was found to be sensitive in detecting a difference in the flank wear and chip forms for the aged and unaged MWF. On the chemistry, the findings suggest that higher total hardness of the aged MWF was the cause of reduced lubricity and accelerated flank wear. This paper discusses the state of the art with the insights that underpin the finish turning method for the machinability assessment of MWFs. The findings point to stabilization of the MWF chemistry to maintain machining process capability over an extended sump life.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Long Sump Life Effects of a Naturally Aged Bio-Ester Oil Emulsion on Tool Wear in Finish Turning a Ni-Based Superalloy

Wood,

Mantle,

Boud

et al. 2023

Metals

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“…Thus, they found an increase of tool life by means of using low cutting speeds with maximum available pressure for both rake and flank. In a more recent study [34], the authors analyzed the HPJC and the chip morphology in turning Inconel 718. They found that increments on the pressure from 8 to 16 MPa, resulted in a decrease on the mean contact area by 13-28% for all pressures at both cutting speed tested.…”

Section: Introductionmentioning

confidence: 99%

“…Conventional/high-pressure Uncoated carbide tools -Tamil Alagan, N. [34] Conventional/high-pressure Uncoated carbide tools -Khochtali, H. [35] Conventional/high-pressure Coated carbide tools -Díaz-Álvarez, A. [23] Haynes 282…”

Section: Introductionmentioning

confidence: 99%

High-Pressure Cooling in Finishing Turning of Haynes 282 Using Carbide Tools: Haynes 282 and Inconel 718 Comparison

Díaz-Álvarez

Cantero

et al. 2021

Metals

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Despite the interest of industry in nickel-based superalloys and its main features (high temperatures resistance, hardness, low thermal conductivity, among others), even today they are still materials that are difficult to cut. Cutting tools withstand both high pressures and temperatures highly localized at the cutting area because of the elevated work hardening of the alloy and the problems for the cutting fluid to access the region, with the consequent strong tool wear. The use of cutting fluids at high pressures improves coolant access and heat removal. This paper analyzed the machining of Haynes 282 alloy by means of coated carbide tools under high-pressure cutting fluids at finishing conditions. Tests were developed at different cutting speeds and feeds quantifying the machining forces, surface roughness, tool wear, and tool life. Values of 45.9 min and Ra between 2 µm and 1 µm were obtained in this study for tool life and roughness, respectively, for the combination of cutting speed 50 m/min and feed 0.1 mm/rev. Likewise, a comparative analysis is included with the results obtained in previous works developed by the authors relating to the finishing turning of Haynes 282 and Inconel 718 under conventional pressure cooling. The comparative analysis with Inconel 718 is included in the study due to its importance within the nickel base superalloys being widely used in industry and widely analyzed in scientific literature.

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Design of an internally cooled green tubular channel for turning application

Murali,

Devendiran

2024

J Braz. Soc. Mech. Sci. Eng.

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High-pressure flank cooling and chip morphology in turning Alloy 718

Cited by 11 publications

References 27 publications

Long Sump Life Effects of a Naturally Aged Bio-Ester Oil Emulsion on Tool Wear in Finish Turning a Ni-Based Superalloy

Long Sump Life Effects of a Naturally Aged Bio-Ester Oil Emulsion on Tool Wear in Finish Turning a Ni-Based Superalloy

High-Pressure Cooling in Finishing Turning of Haynes 282 Using Carbide Tools: Haynes 282 and Inconel 718 Comparison

Design of an internally cooled green tubular channel for turning application

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