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Tool life and surface integrity characteristics in milling of SLM and C&W inconel 718 in dry and MQL condition

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Abstract

In this paper, a tool life test was performed using PVD-coated insert on Inconel 718 (IN718) samples in milling machining. A single cutting condition was considered with two machining environments. The tool life was tested on an IN718 workpiece fabricated through conventional (cast and wrought) and additive (selective laser melting) process routes. The as-built SLM samples were subjected to two heat treatments such as hot isostatic pressing (HIP) and aeronautic heat treatment (AHT). This study aimed to evaluate the machining behavior of C&W and SLM IN718 from the machining point of view such as tool wear, chip appearance, surface roughness, and residual stresses. The tool life tests were performed under two machining environments, such as dry and near dry environment using minimum quantity lubrication (MQL). Meanwhile, the tool wear propagation under different cutting conditions is also explored. Under both the cutting conditions, flank wear and fracture of the cutting edge are the most predominant failure modes minimizing the tool life. The microhardness, surface roughness, and residual stress measurements were analyzed. The result indicates that the microstructural difference between the C&W and SLM has more influence on the tool life compared to the machining environment. On machining, the SLM sample has 80% and 43% more tool life than the C&W in dry and MQL machining. Comparing the dry and MQL machining of SLM, on using MQL, the tool life is 30% less compared to the dry machining.

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All data generated or analyzed during this study are included in this published manuscript.

“The authors declare that submitted work is original and has not been published elsewhere in any form or language.”

Abbreviations

v c :

Cutting speed, m/min

f z :

Feed rate, mm/tooth

a p :

Depth of cut, mm

a e :

Radial depth of cut, mm

v b :

Flank wear, mm

t c :

Cut in time, min

f s :

Chip segmentation frequency (Hz)

∅ :

Cutting-edge angle, degrees

p :

Pitch, µm

t e :

Equivalent chip thickness, µm

t 1 :

Maximum chip thickness, µm

t 2 :

Minimum chip thickness, µm

δ :

Delta phase

γ′:

Gamma single prime

γ″:

Gamma double prime

Q w :

Dissipation of heat in the workpiece, Watts

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Acknowledgements

The authors thank INSA Euromed, University of Fes, Morocco, for the fabrication support and Cutting tool research and study center operators (CEROC, France) for machining support. Institut Pprime gratefully acknowledges “Contrat de Plan Etat–Région Nouvelle-Aquitaine (CPER)” as well as the “Fonds Européen de Développement Régional (FEDER)” for their support to the reported work.

Funding

“The authors declare that no funds or grants were received during the preparation of this manuscript.”

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Authors and Affiliations

  1. Univ. Tours, Univ. Orléans, INSA CVL, LaMé, 7 Avenue Marcel Dassault, 37200, Tours, France

    Sasidharan Periane Natarajan, René Leroy & Arnaud Duchosal

  2. Euromed Research Center, Euromed University of Fes, Fes, Morocco

    Sébastien Vaudreuil

  3. INSA Strasbourg, CSIP, ICube, 24 Boulevard de la Victoire, 67084, Strasbourg Cedex, France

    Hicham Chibane

  4. Advanced Assisted Manufacturing Solutions (AAMS), Bâtiment CEROC, Rue Henri Garih, 37230, Fondettes, France

    Antoine Morandeau

  5. School of Mechanical Engineering, Vellore Institute of Technology, Vellore, 632014, India

    Michael Anthony Xavior

  6. Physics and Mechanics of Materials Department, Institut Pprime, UPR CNRS 3346, ISAE-ENSMA, BP 40109, Futuroscope-Chasseneuil Cedex, 86961, Chasseneuil-du-Poitou, France

    Jonathan Cormier

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  1. Sasidharan Periane Natarajan
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  8. Arnaud Duchosal
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Contributions

Planning and sample fabrication were completed by SébastienVaudreuil, Hicham Chibane, and Sasidharan Periane Natarajan. The heat treatment and material characterization were completed by Jonathan Cormier and Sasidharan Periane Natarajan. The machining tests were completed by Sasidharan Periane Natarajan, Arnaud Duchosal, Antoine Morandeau, and Michael Anthony Xavior. The writing and original draft preparation were done by Sasidharan Periane Natarajan. The supervision and optimization of the article were completed by René Leroy, Arnaud Duchosal, Michael Anthony Xavior, and Jonathan Cormier. All authors have given approval to the final version of the manuscript.

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Correspondence to Sasidharan Periane Natarajan.

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Periane Natarajan, S., Vaudreuil, S., Chibane, H. et al. Tool life and surface integrity characteristics in milling of SLM and C&W inconel 718 in dry and MQL condition. Int J Adv Manuf Technol 121, 647–659 (2022). https://doi.org/10.1007/s00170-022-09327-5

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