Skip to main content
Log in

Effect of Machining Parameters on Surface Integrity in Machining Nimonic C-263 Super Alloy Using Whisker-Reinforced Ceramic Insert

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Whisker-reinforced ceramic inserts were used to conduct turning trials on nimonic C-263 super alloy to study the effect of different combinations of cutting parameters on surface integrity (roughness, microhardness, and residual stress) by employing energy dispersive spectroscopy, scanning electron microscopy, x-ray diffraction, and Vicker’s microhardness test. Abrasion, adhesion and diffusion were found to be the main tool wear mechanisms in turning nimonic C-263 alloy. Based on characterization of surface roughness, a combination of 190 m/min cutting speed and 0.102 mm/rev feed rate was found to be the critical condition for turning nimonic C-263 alloy. Microhardness varied between 550 and 690 HV at the feed rates of 0.102-0.143 mm/rev for a cutting speed of 250 m/min after 9 min of turning. A tensile residual stress of 725-850 MPa on the machined surface was recorded at the preceding combination of cutting parameters. Cutting speed and cutting time had a dominant effect on the magnitude of the residual stress. No evidence of thermal relaxation and reduction in the degree of work hardening was noted during machining at high cutting speed.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

References

  1. J.C. Outeiro, J.C. Pina, R. M’Saoubi, F. Pusavec, and I.S. Jawahir, Analysis of Residual Stresses Induced by Dry Turning of Difficult-to-Machine Materials, CIRP Ann. Manuf. Technol., 2008, 57, p 77–80

    Article  Google Scholar 

  2. I.A. Choudhury and M.A. El-Baradi, Machinability of Nickel-Base Super Alloys: A General Review, J. Mater. Process. Technol., 1998, 77, p 278–284

    Article  Google Scholar 

  3. J. Vigneau and J.J. Boulanger, Behaviour of Ceramic Tools During the Machining of Nickel Base Alloys, Ann. CIRP, 1982, 31, p 35–39

    Article  CAS  Google Scholar 

  4. A. Gatto and L. Iuliano, Advanced Coated Ceramic Tools for Machining Super Alloys, Int. J. Mach. Tools Manuf., 1997, 37, p 591–605

    Article  Google Scholar 

  5. L. Li, N. He, M. Wang, and Z.G. Wang, High Speed Cutting of Inconel 718 With Coated Carbide and Ceramic Inserts, J. Mater. Process. Technol., 2002, 129(1–3), p 127–130

    Article  CAS  Google Scholar 

  6. A. Chakraborty, K.K. Ray, and S.B. Bhaduri, Comparative Wear Behavior of Ceramic and Carbide Tools during High speed Machining of Steel, Mater. Manuf. Process. doi: 10.1080/10426910008912988

  7. T. Kitagawa, A. Kubo, and K. Maekawa, Temperature and Wear of Cutting Tools in High-Speed Machining of Inconel 718 and Ti-6Al-6V-2Sn, Wear, 1997, 202, p 142–148

    Article  CAS  Google Scholar 

  8. D.G. Thakur, B. Ramamoorthy, and L. Vijayaraghavan, An Experimental Analysis of Effective High Speed Turning of Super Alloy Inconel 718, J. Mater. Sci., 2009, 44, p 3296–3304

    Article  CAS  Google Scholar 

  9. D.G. Thakur, B. Ramamoorthy, and L. Vijayaraghavan, Study on the Machinability Characteristics of Super Alloy Inconel 718 During High Speed Turning, Mater. Des., 2009, 30, p 1718–1725

    Article  CAS  Google Scholar 

  10. E.O. Ezugwu and C.I. Okeke, Performance of PVD Coated Carbide Inserts When Machining Nimonic C-263 Alloy at High Speed Conditions, Tribol. Trans., 2000, 43, p 332–336

    Article  CAS  Google Scholar 

  11. E.O. Ezugwu, A. Jawaid. The Effect of Coatings on the Performance of Carbide Cutting Tools When Machining Nickel Base, Inconel 718, Superalloy, Proceedings of the 5th International Manufacturing Conference in China, 1991, p A268–A296

  12. J. Aucote and S.R. Foster, Performance of Sialon Cutting Tools When Machining Nickel Base Aerospace Alloys, Mater. Sci. Technol., 1986, 2, p 700–708

    CAS  Google Scholar 

  13. A.M. El-Tamimi and T.M. Ei-Hossainy, Investigating the Tool Life, Cutting Force Components, and Surface Roughness of AISI, 302 Stainless Steel Material Under Oblique Machining, Mater. Manuf. Processes, 2008, 23, p 427–438

    Article  CAS  Google Scholar 

  14. W. Li, P.J. Withers, D. Axinte, M. Preuss, and P. Andrews, Residual Stresses in Face Finish Turning of High Strength Nickel-Based Super Alloy, J. Mater. Process. Technol., 2009, 209, p 4896–4902

    Article  CAS  Google Scholar 

  15. R.M. Arunachalam, M.A. Mannan, and A.C. Spewage, Residual Stress and Surface Roughness When Facing Age Hardened Inconel 718 with CBN and Ceramic Cutting Tools, Mach. Tools Manuf., 2004, 44, p 879–887

    Article  Google Scholar 

  16. T. Berruti, M. Lavella, and M.M. Gola, Residual Stresses on Inconel 718 Turbine Shaft Samples After Turning, Mach. Sci. Technol., 2009, 13, p 543–560

    Article  CAS  Google Scholar 

  17. D. Ulutana and T. Ozel, Machining Induced Surface Integrity in Titanium and Nickel Alloys: A Review, Int. J. Mach. Tools Manuf., 2011, 51, p 250–280

    Article  Google Scholar 

  18. S.C. Veldhuis, G.K. Dosbaeva, A. Elfizy, G.S. Fox-Rabinovich, and T. Wagg, Investigations of White Layer Formation During Machining of Powder Metallurgical Ni-Based ME 16 Superalloy, J. Mater. Eng. Perform., 2010, 19, p 1031–1036

    Article  CAS  Google Scholar 

  19. M.C. Shaw, Metal Cutting Principles, 2nd ed., Oxford University Press, New York, 2005, p 432–454

    Google Scholar 

  20. K. Ankamma, D.V.V. Satyanarayana, G. Chandramohan Reddy, M. Komaraiah, and N. Eswara Prasad, In-Plane Anisotropy in Tensile Deformation and Its Influence on the Drawability of Nimonic C-263 Alloy Sheets, Sādhanā, 2011, 36, p 223–249

    CAS  Google Scholar 

  21. Y.B. Guo, W. Li, and I.S. Jawahir, Surface Integrity Characterization and Prediction in Machining of Hardened and Difficult-to-Machine Alloys; A State-of-the-Art Research Review and Analysis, Mach. Sci. Technol., 2009, 13, p 437–470

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to V. S. Senthil kumar.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Ezilarasan, C., Senthil kumar, V.S. & Velayudham, A. Effect of Machining Parameters on Surface Integrity in Machining Nimonic C-263 Super Alloy Using Whisker-Reinforced Ceramic Insert. J. of Materi Eng and Perform 22, 1619–1628 (2013). https://doi.org/10.1007/s11665-012-0439-1

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-012-0439-1

Keywords

Navigation