Temperature Measurement and Numerical Prediction in Machining Inconel 718

Díaz-Álvarez, José; Tapetado, A.; Vázquez, Carmen; Miguélez, H.

doi:10.3390/s17071531

Cited by 43 publications

(28 citation statements)

References 27 publications

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“…274W in this case) due to material softening by laser and only a small portion (e.g. 17% [46] ) was conducted to the workpiece. In addition, the additional heat losses on the upper surface due to the air turbulence induced by cutting tool might also neutralize the contribution of machining generated heat.…”

Section: Inverse Problem Verificationmentioning

confidence: 99%

On modelling of laser assisted machining: Forward and inverse problems for heat placement control

Shang

Liao

Sarasua

et al. 2019

International Journal of Machine Tools and Manufacture

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Laser assisted machining (LAM) is one of the most efficient ways to improve the machinability of difficultto-cut materials (e.g. Nickel-based superalloys). In the conventional LAM process, the laser beam is focused ahead of the cutting area at a fixed location, which leads to a series of restrictions, e.g. small heating area and non-uniform heat distribution due to the limitation of beam size and energy distribution. In this paper, a novel spatially and temporally (S&T) controlled laser heating method was proposed, in which a large area can be heated up with a small laser spot by controlling the beam scanning, i.e., laser power, path and speed of scanning. The laser configuration for the prescribed HAZ (heat affected zone) was achieved by solving the inverse problem where the laser power together with either laser path or laser speed were optimised to achieve a particular temperature distribution in the chip to be removed by the following milling cutter. The proposed S&T laser heating method was thoroughly validated both for the forward and, the more important, inverse heating models by performing extensive temperature experiments by both infrared thermal camera and thermocouple array and further verified by laser assisted milling (LAMill) tests of Inconel 718 for large widths of cuts. The results showed that by applying path-optimised LAMill based on the inverse solution of the thermal problem, the peak and mean principal cutting forces were reduced by 55% and 47.8% respectively compared with the conventional dry milling process while the surface roughness improved by at least 14%. Moreover, after controlling the HAZ using the inverse thermal problem, a microstructure analysis of the machined surface showed that the proposed laser heating method avoids overheating of the workpiece below the planned depth of cut for the milling operation.

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Section: Inverse Problem Verificationmentioning

confidence: 99%

On modelling of laser assisted machining: Forward and inverse problems for heat placement control

Shang

Liao

Sarasua

et al. 2019

International Journal of Machine Tools and Manufacture

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“…Increased feed induces more elevated forces and unstable cutting, favoring the appearance of brittle breakages at the cutting edge. The increment of cutting speed results in enhanced temperature at the cutting zone [20], promoting the adhesion of the workpiece material to the tool and instabilities during cutting, leading to chipping.…”

Section: Tool Wear and Tool Lifementioning

confidence: 99%

“…Tool wear mechanisms are generally related to friction at the contact interface between the tool, the chip, and the machined surface. The abrasive particles contained in nickel alloys, together with the low thermal conductivity and work hardening, cause elevated temperatures of up to 1200 • C [19,20], promoting wear by oxidation, diffusion, and abrasion. Furthermore, during the machining of nickel-based superalloys, welding and adhesion of the material to the tool occurs, causing damage on the tool rake face [1,15].…”

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confidence: 99%

Finishing Turning of Ni Superalloy Haynes 282

Díaz-Álvarez

Miguélez

et al. 2018

Metals

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Nickel-based superalloys are widely used in the aeronautical industry, especially in components requiring excellent corrosion resistance, enhanced thermal fatigue properties, and thermal stability. Haynes 282 is a nickel-based superalloy that was developed to improve the low weldability, formability, and creep strength of other γ’-strengthened Ni superalloys. Despite the industrial interest in Haynes 282, there is a lack of research that is focused on this alloy. Moreover, it is difficult to find studies dealing with the machinability of Haynes 282. Although Haynes 282 is considered an alloy with improved formability when compared with other nickel alloys, its machining performance should be analyzed. High pressure and temperature localized in the cutting zone, the abrasion generated by the hard carbides included in the material, and the tendency toward adhesion during machining are phenomena that generate extreme thermomechanical loading on the tool during the cutting process. Excessive wear results in reduced tool life, leading to frequent tool change, low productivity, and a high consumption of energy; consequentially, there are increased costs. With regard to tool materials, cemented carbide tools are widely used in different applications, and carbide is a recommended cutting material for turning Haynes 282, for both finishing and roughing operations. This work focuses on the finishing turning of Haynes 282 using coated carbide tools with conventional coolant. Machining forces, surface roughness, tool wear, and tool life were quantified for different cutting speeds and feeds.

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“…In general, due to the low machinability of superalloys, the use of cutting fluid is highly recommended to decrease friction, help with the chip disposal and reduce the temperatures reached during the machining of Inconel 718 [15]. However, increasing concern by governments and society about environmental sustainability of industrial activities has driven manufacturers to implement alternative, greener techniques to be used instead of traditional cutting fluids [16].…”

Section: Introductionmentioning

confidence: 99%

High Speed Finish Turning of Inconel 718 Using PCBN Tools under Dry Conditions

Cantero

Díaz-Álvarez

Infante-García

et al. 2018

Metals

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Inconel 718 is a superalloy, considered one of the least machinable materials. Tools must withstand a high level of temperatures and pressures in a very localized area, the abrasiveness of the hard carbides contained in the Inconel 718 microstructure and the adhesion tendency during its machining. Mechanical properties along with the low thermal conductivity become an important issue for the tool wear. The finishing operations for Inconel 718 are usually performed after solution heat treatment and age hardening of the material to give the superalloy a higher level of hardness. Carbide tools, cutting fluid (at normal or high pressures) and low cutting speed are the main recommendations for finish turning of Inconel 718. However, dry machining is preferable to the use of cutting fluids, because of its lower environmental impact and cost. Previous research has concluded that the elimination of cutting fluid in these processes is feasible when using hard carbide tools. Recent development of new PCBN (Polycrystalline Cubic Boron Nitride) grades for cutting tools with higher tenacity has allowed the application of these tool grades in the finishing operations of Inconel 718. This work studies the performance of commercial PCBN tools from four different tool manufacturers as well as an additional grade with equivalent performance during finish turning of Inconel 718 under dry conditions. Wear tests were carried out with different cutting conditions, determining the evolution of machining forces, surface roughness and tool wear. It is concluded that it is not industrially viable the high-speed finishing of Inconel 718 in a dry environment.

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Temperature Measurement and Numerical Prediction in Machining Inconel 718

Cited by 43 publications

References 27 publications

On modelling of laser assisted machining: Forward and inverse problems for heat placement control

On modelling of laser assisted machining: Forward and inverse problems for heat placement control

Finishing Turning of Ni Superalloy Haynes 282

High Speed Finish Turning of Inconel 718 Using PCBN Tools under Dry Conditions

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