Nickel-Based Alloy Dry Milling Process Induced Material Softening Effect

Abstract

Improving the cutting efficiency is the major factor for improving the processing of nickel-based alloys. The novelty of this research is the calibrated SiAlON ceramic tool dry milling nickel-based alloy process. Firstly, the nickel-based alloy dry milling process was analyzed through the finite element method, and the required milling force and temperature were deduced. Then, several dry milling experiments were conducted with the milling temperature, and the milling force was monitored. The change in cutting speeds was from 400 m/min to 700 m/min. Experimental results verified the reduction of the dry milling force hypothesized by the simulation. The experiment also indicated that with a cut depth of 0.3 mm, cut width of 6 mm, and feed per tooth of 0.03 mm/z, when milling speed exceeded 527.52 m/min, the milling force began to decrease, and the milling temperature exceeded the nickel-based alloy softening temperature. This indicated that easy cutting could be realized under high-speed dry milling conditions. The interpolation curve about average temperature and average milling forces showed similarity to the tensile strength reduction with the rise of temperature.

Cutting Behavior of Al0.6CoCrFeNi High Entropy Alloy

“…Roughness and surface topology are investigated based on optimization of parameters such as cutting speed and feed rate to minimize surface roughness in turning of a titanium alloy (Ti-6Al-4V) [32] and machining of CoCrMo alloy [33], or using a mathematical model of the relative position between cutting tool and machined surface in cutting of low carbon alloy hardened steel [34]. Zha et al [35] brought important contributions on improving the cutting efficiency in the processing of nickel-based alloys using the finite element method and analysis of cutting forces and temperature.…”

Tool life and wear mechanisms of CVD coated and uncoated SiAlON ceramic milling inserts when machining aged Inconel 718

“…These secondary wear mechanisms are due to the high cutting forces being transmitted through the inserts, which in turn causes the rake face of the insert structure to shear along the grain boundary, Li et al 16 suggests that high cutting speeds in excess of 500 m/min in accordance with the feed rate of 0.06 mm/rev should be adopted to minimise insert flank wear and the required specific cutting force by exploiting the thermo-mechanical softening of the workpiece that take place at higher cutting speeds. Higher induced material softening takes place above 650 m/min, which ultimately has a positive effect on tool life and flank wear rates as discovered by Zha et al 17…”

“…[13][14][15] These secondary wear mechanisms are due to the high cutting forces being transmitted through the inserts, which in turn causes the rake face of the insert structure to shear along the grain boundary, Li et al 16 suggests that high cutting speeds in excess of 500 m/min in accordance with the feed rate of 0.06 mm/rev should be adopted to minimise insert flank wear and the required specific cutting force by exploiting the thermomechanical softening of the workpiece that take place at higher cutting speeds. Higher induced material softening takes place above 650 m/min, which ultimately has a positive effect on tool life and flank wear rates as discovered by Zha et al 17 To date the most relevant research that has been published has focused on utilising coated SiAlON ceramic milling inserts for milling cast iron and steels, which is the main driver of this research. Earlier turning and tribological studies [18][19][20][21][22][23] that have utilised coated ceramic indexable inserts, have all stated that applying protective physical vapour deposition (PVD) and chemical vapour deposition (CVD) wear resistant coatings will improve the wear resistance and overall cutting performance of SiAlON inserts when machining steels and cast irons.…”

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

“…Although Molaiekiya et al [124] systematically studied the HSDM process of SiAlON ceramic tools, the hardness of the hard white layer and cutting forces were not explored under HSDM and CM conditions. To determine the change in hardness, Şirin et al [125] used HSDM and SiAlON ceramic tools to process nickelbased X-750 alloys. The surface roughness, cutting temperature, cutting force, and microhardness of the workpiece were measured in the v c range of 500-700 m/min, and the v f range of 0.025-0.075 mm/r.…”

“…The tool wear was small because the tool coating provided anti-wear properties during processing. Compared with CM pouring cutting, HSDM can increase the hardness of the workpiece by 16.94% [125].…”