Wear mechanism and notch wear location prediction model in ball nose end milling of Inconel 718

Kasim, Mohd Shahir; Haron, Che Hassan Che; Ghani, Jaharah A.; Sulaiman, Mohd Amri; Yazid, Mohd Faizun Mohamad

doi:10.1016/j.wear.2012.12.040

Cited by 92 publications

(44 citation statements)

References 36 publications

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“…The modes of tool deterioration [11] and how the progression of tool deterioration affects F [12], explained for end milling of a nickel-based superalloy, have been based on a f t value of 0.05 mm/tooth. This value appears to be (or to be close to) the most commonly used value in nickel-based superalloy milling research [7,8,[13][14][15][16][17][18][19]. As has been explained [12], using f t of 0.05 mm/tooth, the edge radius of even the new tools is approximately the same as the un-cut chip thickness.…”

Section: Introductionsupporting

confidence: 58%

“…In the milling of nickel-based superalloys, feed rate, defined as the forward distance per tooth in each revolution (ft), is generally low, but the values used in various studies vary considerably, ranging from 0.0075 to 0.2 mm/tooth [7,8,[13][14][15][16][17][18][19]. It has been suggested that ft is a dominant factor for tool life and that lowering ft may increase the tool life [14,17], although the tool life taking into account material removal has not been well clarified.…”

Section: Introductionmentioning

confidence: 99%

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Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool

Razak

Chen

Pasang

2017

Metals

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Understanding how feed rate (f t ) affects tool deterioration during milling of Ni-based superalloys is practically important, but this understanding is currently insufficient. In the present study using a 718Plus Ni-based alloy and cemented tungsten carbide tool inserts, milling experiments were conducted with f t = 0.10 mm/tooth under either dry or wet (with coolant) conditions. The results are compared to those based on using f t = 0.05 mm/tooth from previous studies. The milling force (F) was monitored, the cutting tool edge was examined and the flank wear (VB max ) was measured. As would be expected, an increase in f t increased F. It was found that F correlated well with VB max for the high f t (0.1 mm/tooth) experiments, as opposed to the previously observed poor F-VB max relationship for the lower f t (0.05 mm/tooth) value. This is explained, supported by detailed failure analysis of the cutting tool edges, by the deterioration mode to be dominantly edge chipping with a low occurrence of fracturing along the flank face when the high f t was used. This dominancy of the deterioration mode means that the tool edge and workpiece contact was consistent and thus resulted in a clear F-VB max relationship. A clear F-VB max relationship should then mean monitoring VB max through monitoring F is possible.

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Section: Introductionsupporting

confidence: 58%

Section: Introductionmentioning

confidence: 99%

Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool

Razak

Chen

Pasang

2017

Metals

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“…Na granicy ziaren w strukturze krystalicznej stopu INCONEL ulokowane są twarde węgliki NiC, CrC, TiC, MoC, WC, FeC oraz NbC, które wyrwane z materiału, powodują niekorzystne bruzdy na powierzchni obrabianego przedmiotu [7,12]. Zawartość wspomnianych związków chemicznych w objętości skrawanego materiału przyczynia się również do przyspieszonego zużycia części roboczej narzędzia skrawającego.…”

Section: Badania Porównawcze Wybranych Wskaźników Skrawalności W Procunclassified

Comparative research on selected machinability indicators of nickel alloy milling – INCONEL 625 and INCONEL 718

Bławucki¹,

Matuszak²,

Zaleski³

2015

Mechanik

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StreszczenieStopy niklu są cennym materiałem konstrukcyjnym, stosowanym w przemyśle lotniczym, energetycznym i chemicznym. Wytwarzanie elementów z tych stopów wiąże się z dużymi problemami ze względu na ich trudnoobrabialność. W pracy przedstawiono wyniki badań eksperymentalnych składo-wych siły skrawania oraz chropowatości powierzchni w procesie frezowania czołowego trudnoobrabialnych stopów niklu INCONEL 625 i INCONEL 718. Badania prowadzono przy zmiennych parametrach technologicznych. Słowa kluczowe: stopy niklu, wskaźniki skrawalności, frezowanie czołowe COMPARATIVE RESEARCH ON SELECTED MACHINABILITY INDICATORS OF NICKEL ALLOY MILLING -INCONEL 625 AND INCONEL 718Abstract Nickel alloys are valuable constructional materials, used in aircraft, power and chemical industry. These alloys are hard to machine, so production of nickel alloy parts causes some difficulties. This paper presents experimental research results of cutting force, and the surface roughness in face milling of INCONEL 625 and INCONEL 718 nickel alloys, which are difficult to machine. Research was conducted with variable technological parameters.

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“…The results indicated a reduction in 30-40 % Ra and Rz respectively [11]. Kasim et al (2013) investigated the tool wear by using a ball type end mill. A PVD coated tool was used and the cutting parameters were varied.…”

Section: Introduction and Literature Surveymentioning

confidence: 99%

“…Celsius was recorded which was far lower than the critical temperature of 650 deg. Celsius [12]. Ucun et al (2013) studied the effect of coating material on the tool wear in comination with the MQL process.…”

Section: Introduction and Literature Surveymentioning

confidence: 99%

Parametric Optimization Using The Particle Swarm Optimization (PSO) Technique for Minimizing Tool Wear While Milling Inconel 718 Alloy Assisted by Minimum Quantity Lubrication (MQL)

Sharma¹,

Singh²,

Sørby³

2016

Proceedings of the 6th International Workshop of Advanced Manufacturing and Automation

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Abstract-In today's industrial scenario, the high cost involved in manufacturing is the major concern apart from the environmental factors. With the manufacturing cost reaching sky high levels, the use of a suitable optimization technique has become one major requirement while designing any manufacturing process. The current study involves a series of milling experiments on Inconel 718 alloy. Minimum quantity lubrication has been used as the cooling technique alongside the flood and the dry conditions. The combined objective functions were generated using ANOVA. Particle swarm optimization (PSO) technique was used to optimize the input parameters i.e. the cutting speed (Vc), cutting feed (F) and the depth of cut (ae) in order to minimize the tool wear (Vbmax). A series of validation experiments were performed and the PSO technique proved to be a highly effective method in predicting the tool wear (Vbmax), also allowing a simultaneous comparison amongst the cooling methods, thus, suggesting MQL to be a better cooling technique when compared to the dry and the flood cooling.

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Wear mechanism and notch wear location prediction model in ball nose end milling of Inconel 718

Cited by 92 publications

References 36 publications

Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool

Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool

Comparative research on selected machinability indicators of nickel alloy milling – INCONEL 625 and INCONEL 718

Parametric Optimization Using The Particle Swarm Optimization (PSO) Technique for Minimizing Tool Wear While Milling Inconel 718 Alloy Assisted by Minimum Quantity Lubrication (MQL)

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