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Study of cutting speed on surface roughness and chip formation when machining nickel-based alloy

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Abstract

Nickel-based alloy is difficult-to-machine because of its low thermal diffusive property and high strength at higher temperature. The machinability of nickel- based Hastelloy C-276 in turning operations has been carried out using different types of inserts under dry conditions on a computer numerical control (CNC) turning machine at different stages of cutting speed. The effects of cutting speed on surface roughness have been investigated. This study explores the types of wear caused by the effect of cutting speed on coated and uncoated carbide inserts. In addition, the effect of burr formation is investigated. The chip burr is found to have different shapes at lower speeds. Triangles and squares have been noticed for both coated and uncoated tips as well. The conclusion from this study is that the transition from thick continuous chip to wider discontinuous chip is caused by different types of inserts. The chip burr has a significant effect on tool damage starting in the line of depth-of-cut. For the coated insert tips, the burr disappears when the speed increases to above 150 m/min with the improvement of surface roughness; increasing the speed above the same limit for uncoated insert tips increases the chip burr size. The results of this study showed that the surface finish of nickel-based alloy is highly affected by the insert type with respect to cutting speed changes and its effect on chip burr formation and tool failure.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering, Universiti Tenaga Nasional, Kajang, Malaysia

    Basim A. Khidhir & Bashir Mohamed

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  1. Basim A. Khidhir
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  2. Bashir Mohamed
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Correspondence to Basim A. Khidhir.

Additional information

This paper was recommended for publication in revised form by Associate Editor Dae-Eun Kim

Basim A. Khidhir, PhD candidate 2008, MSc production engineering (Metal Cutting) 1992; BSc Production engineering (metal cutting) 1985. Senior lecturer in Sulaimanyah Technical College. He has published many papers in different journals in the field of metal cutting.

Bashir Mohamad, PhD Mechanical Enginering 1995; BSc Mechanical Engineering 1981. Associate Professor in Universiti Tenaga Nasional, Malaysia. He has published many papers in different journals in the field of manufacturing and metal cutting.

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Khidhir, B.A., Mohamed, B. Study of cutting speed on surface roughness and chip formation when machining nickel-based alloy. J Mech Sci Technol 24, 1053–1059 (2010). https://doi.org/10.1007/s12206-010-0319-2

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  • DOI: https://doi.org/10.1007/s12206-010-0319-2

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