Towards understanding the thermal history of microstructural surface deformation when cutting a next generation powder metallurgy nickel-base superalloy

Monaca, Andrea la; Axinte, Dragoş; Liao, Zhirong; M’Saoubi, Rachid; Hardy, Mark

doi:10.1016/j.ijmachtools.2021.103765

Cited by 43 publications

(7 citation statements)

References 33 publications

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“…In the latter study, the factors affecting the accuracy of the IR-camera measurements were also evaluated, indicating the necessity for more precise emissivity calibrations. Kryzhanivskyy et al [82], Monica et al [99], Jafarian et al [100] and Liao et al [101] used IR-camera measurements to investigate the effect of cutting temperature on the surface microstructure of the workpiece and used their findings to inform their predictive FE models.…”

Section: Infrared Camerasmentioning

confidence: 99%

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

Leonidas

Ayvar-Soberanis

Laalej

et al. 2022

Sensors

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During the machining process, substantial thermal loads are generated due to tribological factors and plastic deformation. The increase in temperature during the cutting process can lead to accelerated tool wear, reducing the tool’s lifespan; the degradation of machining accuracy in the form of dimensional inaccuracies; and thermally induced defects affecting the metallurgical properties of the machined component. These effects can lead to a significant increase in operational costs and waste which deviate from the sustainability goals of Industry 4.0. Temperature is an important machining response; however, it is one of the most difficult factors to monitor, especially in high-speed machining applications such as drilling and milling, because of the high rotational speeds of the cutting tool and the aggressive machining environments. In this article, thermocouple and infrared radiation temperature measurement methods used by researchers to monitor temperature during turning, drilling and milling operations are reviewed. The major merits and limitations of each temperature measurement methodology are discussed and evaluated. Thermocouples offer a relatively inexpensive solution; however, they are prone to calibration drifts and their response times are insufficient to capture rapid temperature changes in high-speed operations. Fibre optic infrared thermometers have very fast response times; however, they can be relatively expensive and require a more robust implementation. It was found that no one temperature measurement methodology is ideal for all machining operations. The most suitable temperature measurement method can be selected by individual researchers based upon their experimental requirements using critical criteria, which include the expected temperature range, the sensor sensitivity to noise, responsiveness and cost.

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Section: Infrared Camerasmentioning

confidence: 99%

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

Leonidas

Ayvar-Soberanis

Laalej

et al. 2022

Sensors

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“…Microstructural surface modifications are caused by a variety of physical mechanisms [12]. The effects of process parameters are thus complex and must be examined in detail for different types of surface modification.…”

Section: Causes and Modification Of Surface Layer Statesmentioning

confidence: 99%

The Present State of Surface Conditioning in Cutting and Grinding

Stampfer

González

Gerstenmeyer

et al. 2021

JMMP

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All manufacturing processes have an impact on the surface layer state of a component, which in turn significantly determines the properties of parts in service. Although these effects should certainly be exploited, knowledge on the conditioning of the surfaces during the final cutting and abrasive process of metal components is still only extremely limited today. The key challenges in regard comprise the process-oriented acquisition of suitable measurement signals and their use in robust process control with regard to the surface layer conditions. By mastering these challenges, the present demands for sustainability in production on the one hand and the material requirements in terms of lightweight construction strength on the other hand can be successfully met. In this review article completely new surface conditioning approaches are presented, which originate from the Priority Program 2086 of the Deutsche Forschungsgemeinschaft (DFG).

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“…Owing to these characteristics, achieving high technological parameters is not feasible using metal During chip removal, three distinct zones emerge at the contact of the tool and workpiece surfaces. These are the primary shear zone (PSZ), characterized by the rapid shearing of metal volumes transitioning from the workpiece material into the forming chip; the secondary shear zone (SSZ), which forms due to friction at the tool-chip interface; and the tertiary shear zone (TSZ), where plastic deformation occurs because of the interaction between the newly machined surface of the workpiece and the tool flank [22]. In these zones, intense friction leads to the generation of high temperatures and extremely elevated local loads [23].…”

Section: Introductionmentioning

confidence: 99%

Effects of Oil Concentration in Flood Cooling on Cutting Force, Tool Wear and Surface Roughness in GTD-111 Nickel-Based Superalloy Slot Milling

Kónya,

Kovács

2024

JMMP

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Cooling–lubricating processes have a big impact on cutting force, tool wear, and the quality of the machined surface, especially for hard-to-machine superalloys, so the choice of the right cooling–lubricating method is of great importance. Nickel-based superalloys are among the most difficult materials to machine due to their high hot strength, work hardening, and extremely low thermal conductivity. Previous research has shown that flood cooling results in the least tool wear and cutting force among different cooling–lubricating methods. Thus, the effects of the flood oil concentration (3%; 6%; 9%; 12%; and 15%) on the above-mentioned factors were investigated during the slot milling of the GTD-111 nickel-based superalloy. The cutting force was measured during machining with a Kistler three-component dynamometer, and then after cutting the tool wear and the surface roughness on the bottom surface of the milled slots were measured with a confocal microscope and tactile roughness tester. The results show that at a 12% oil concentration, the tool load and tool wear are the lowest; even at an oil concentration of 15%, a slight increase is observed in both factors. Essentially, a higher oil concentration reduces friction between the tool and the workpiece contact surface, resulting in reduced tool wear and cutting force. Furthermore, due to less friction, the heat generation in the cutting zone is also reduced, resulting in a lower heat load on the tool, which increases tool life. It is interesting to note that the 6% oil concentration had the highest cutting force and tool wear, and strong vibration was heard during machining, which is also reflected in the force signal. The change in oil concentration did not effect the surface roughness.

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Towards understanding the thermal history of microstructural surface deformation when cutting a next generation powder metallurgy nickel-base superalloy

Cited by 43 publications

References 33 publications

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

The Present State of Surface Conditioning in Cutting and Grinding

Effects of Oil Concentration in Flood Cooling on Cutting Force, Tool Wear and Surface Roughness in GTD-111 Nickel-Based Superalloy Slot Milling

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