Wear mechanisms of Syalon ceramic tools when machining nickel-based materials

Bhattacharyya, S. K.; Jawaid, A.; Lewis, M. H.; Wallbank, J.

doi:10.1179/030716983803291415

Cited by 38 publications

(13 citation statements)

References 4 publications

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“…Depth of cut notching is a major tool failure process encountered while machining nickel-based alloys, and consequently, significant research has been conducted to understand this phenomenon. Various factors including rubbing against heavily work-hardened material (such as burrs) [21][22][23][24], lateral chip flow [24], high stress gradients [25], chip adhesion and pull out [14,21,23], fatigue loading [14,21,22], attrition and diffusion processes [26,27] are all believed to be responsible for notch formation. Considering the vast evidence available on the subject, it is almost certain that multiple mechanisms influence notch formation, depending on cutting tool and work-piece material combinations [28].…”

Section: Tool Failure Modementioning

confidence: 99%

Tool life and wear mechanisms in laser assisted milling Ti–6Al–4V

Bermingham

Sim

Kent

et al. 2015

Wear

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Thermally assisted machining processes are gaining popularity among researchers and engineers as a method for improving the machinability of difficult-to-cut materials such as titanium. The process of artificially introducing heat to the cutting zone is reported to have many benefits; however, it remains unclear whether the process offers any tool life improvements during milling Ti-6Al-4V when compared to conventional milling processes. This paper compares the tool life during laser assisted milling, dry milling, milling with flood emulsion, milling with minimum quantity lubrication (MQL) and a hybrid laser + MQL process. It is found that conventional coolants offer superior tool life at the standard cutting speeds recommended by the tooling manufacturer, but at higher speeds the coolant deteriorates tool life due to thermal shock/fatigue. Despite this, laser assisted machining performed poorly and exacerbated thermally related tool wear mechanisms such as adhesion, diffusion and attrition. Hybrid laser + MQL substantially improved tool life by suppressing the thermal wear processes while also preventing thermal fatigue on the cutting tool.

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Section: Tool Failure Modementioning

confidence: 99%

Tool life and wear mechanisms in laser assisted milling Ti–6Al–4V

Bermingham

Sim

Kent

et al. 2015

Wear

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“…The effect of the H P cooling system is thus to increase the notch wear rate and shorten tool life when machining the nickel alloy. The possible effect of chemical interactions suggested by Bhattacharyya et al (23) may also play a part in the process. Measurement of the flank wear proved that if the notch wear could be s u p pressed the H P cooling system would have given better tool lives than the CW system in exactly the same way as when machining Ti6A14V.…”

Section: Part 8: Journal Of Engineering Manufacturementioning

confidence: 99%

The Effects of a High-Pressure Coolant Jet on Machining

Machado

Wallbank

1994

Proceedings of the Institution of Mechanical Engineers, Part B:

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A high-pressure coolant system was used to machine Ti6A14V and Inconel 901. A 14.5 MPa jet of cuttingfluid was applied against the chip$ow at the rake face of the tool and this works as an efficient chip-breaker. Conventional overheadflood cooling was also used to establish a base for comparison. Chip control, cutting force, cutting temperature, chip-tool contact length, surface integrity, tool lives and wear mechanisms were studied. The high-pressure coolant system used improved tool lives significantly when makhining the titanium alloy but it proved to be detrimental to tool lives when machining the nickel alloy.

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“…In high-speed machining of Inconel 718, the wear of ceramic tools can be accelerated due to diffusional wear (due to the diffusion of silicon) caused by high cutting temperature [13]. Bhattacharyya et al found that a diffusion zone formed between the SiAlON ceramic tool and Inconel 901 above a speed of 185 m/min [14]. Addhoum and Broussaud studied the interaction between ceramic cutting tools and nickel-based alloys and also found it to be governed by diffusion of silicon that occurred at temperatures above 1100 °C [15].…”

Section: Introductionmentioning

confidence: 99%