Study of machining parameter optimization in high speed milling of Inconel 718 curved surface based on cutting force

Abstract

Nickel-based alloy Inconel 718 is a kind of difficult-to-machine material, and the development of highspeed milling technology provides an effective machining method for the Inconel 718 parts. As the machining parameters play a crucial role in the high-speed milling of Inconel 718 parts, a lot of researches on the optimization of machining parameters have been conducted, and the optimum machining parameters under different test conditions have been obtained according to the experiments of flank milling or slot milling of Inconel 718. However, the machining parameter optimization in high-speed milling of Inconel 718 curved surface is seldom involved. The variation of the geometric features of the curved surface results in the sharp fluctuation of the cutting force as well as the vibration of the machine tool, which not only makes a severe impact on the surface machining quality and the tool life but also greatly affects the efficiency of the highspeed milling. In the machining process of the Inconel 718 parts with curved surface, the change of cutting force in highspeed milling should be smooth as far as possible. In this study, the experimental study is carried out on machining parameter optimization in high-speed milling of Inconel 718 curved surface based on the cutting force. The relationship between the cutting force and the spindle speed is analyzed, and in particular, the machining parameter optimization is investigated. The experiment results indicate that the cutting force relates to the geometric feature of curved surface, the cutting force is relatively smaller and the change of cutting force is smoother when the spindle speed changes from 4,000 to 4,500 rpm, the effect of the feed per tooth on the cutting force is little, and the cutting depth should be small to lessen the fluctuation of the cutting force. The research results can be considered to improve the machining quality of Inconel 718 parts with curved surface and will enrich the processing and manufacturing theory for the Inconel 718 parts.

A new cutting force modeling method in high-speed milling of curved surface with difficult-to-machine material

“…The workpiece used in this study is Inconel 718 sheet material with the size of 50×50×30 mm, and the Inconel 718 curved surface which is set as a test piece is an extruded surface whose generatrix is a sine curve, just the same as in Reference [31]. The formulation of the sine curve is designed as y ¼ 4sin πx 26 À Á , and the machining path of cutting tool is along with the generatrix of the sine curve.…”

“…8. From the resultant cutting force, it can be seen that as the change of geometric feature of curved surface, the sharp fluctuation of the cutting force can be observed at the certain machining parameters, which would influence the machining quality of the Inconel 718 parts with curved surface [31]. After analyzing in Fig.…”

Onset and evolution of discontinuously segmented chip flow in ultra-high-speed cutting Ti-6Al-4V

“…The growing demand for enhancing production efficiency and product quality has led to the rapid development of high-speed cutting or machining technology [1][2][3]. In spite of extensive studies, several fundamental aspects of the high-speed cutting process are poorly understood.…”

Development of a Tri-Axial Cutting Force Sensor for the Milling Process

“…Cutting force is a significant feature in milling procedure as it is closely related to process optimization [ 1 ], tool design [ 2 , 3 ], as well as tool condition monitoring [ 4 ], etc . A cutting force monitoring system could provide a fundamental reference for identification of milling conditions and also offer the basis for parameter modification or tool selection.…”