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Study on surface defects in milling Inconel 718 super alloy

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Abstract

Nickel-based alloys have been extensively used as critical components in aerospace industry, especially in the key section of aeroengine. In general, these sections are manufactured by milling process because most of them have complex forms. However, surface defects appear frequently in milling due to periodic impact force, which leads to the deterioration of the fatigue life. We conducted milling experiments under different cutting conditions and found that four kinds of defects, i.e., tear, cavity, build up edge (BUE) and groove, commonly appear on the machined surface. Based on the observed results, the morphology and generation regime of these defects are analyzed and the carbide particle cracking is discussed to explain the appearance of the nickel alloy defects. To study the effect of the cutting parameters on the severity of these surface defects, two qualitative indicators, which are named as average number of the defects per field and average area ratio of the defects per field, are presented and the influence laws are summarized based on the results correspondingly. This study is helpful for understanding the generation mechanism of the surface defects during milling process of nickel based super alloy.

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Authors and Affiliations

  1. Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin, China

    Chang Liu, Chengzu Ren, Guofeng Wang, Yinwei Yang & Lu Zhang

Authors
  1. Chang Liu
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  2. Chengzu Ren
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  3. Guofeng Wang
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  4. Yinwei Yang
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  5. Lu Zhang
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Corresponding author

Correspondence to Guofeng Wang.

Additional information

Recommended by Associate Editor Jihong Hwang

Liu Chang received his B.S. and M.E. degrees in Mechanical Engineering from Tianjin University of Technology, Tianjin, China in 2010 and 2012. Currently, he is a Ph.D. student there in Mechanical Engineering His main research interests include vibration test and analysis, precision machining and detection analysis of surface quality.

Ren Chengzu received his M.E. degree in Mechanical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China in 1987. His Ph.D. is in Mechanical Engineering, Tianjin University, 1995. Currently, he is a professor of Mechanical Engineering at Tianjin University. His main research interests include design theory and manufacture technology of ceramic rolling bearing, the theory and key technology of ultra-precision machining.

Wang Guofeng received his B.S., M.E. and Ph.D. degrees in Mechanical Engineering, Tianjin University in 1996, 1999 and 2002, respectively. Currently, he is an associate professor in Mechanical Engineering at Tianjin University. His research interests include dynamic modeling and condition monitoring of machining process.

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Liu, C., Ren, C., Wang, G. et al. Study on surface defects in milling Inconel 718 super alloy. J Mech Sci Technol 29, 1723–1730 (2015). https://doi.org/10.1007/s12206-015-0345-1

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  • DOI: https://doi.org/10.1007/s12206-015-0345-1

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