Advertisement

Progression of tool deterioration and related cutting force during milling of 718Plus superalloy using cemented tungsten carbide tools

  • N. H. Razak
  • Z. W. Chen
  • T. Pasang
ORIGINAL ARTICLE

Abstract

Understanding how tool deterioration affects total force (F) during milling of Ni-based superalloys is important for the improvement of machinability of the alloys and serves to clarify whether and how an F-based method for monitoring tool deterioration is possible. In this study, a series of milling experiments have been conducted on 718Plus Ni-based alloy using cemented tungsten carbide tool inserts. F was monitored, and the conventional flank wear (VB max ) to represent insert deterioration was measured. As would be expected, the general trend of how F increased as the number of milling pass (N pass ) increased agreed with the general trend of increasing VB max as N pass increased. But the F-VB max plot has shown a rather poor F-VB max relationship. This was the results of the different modes of tool deterioration affecting VB max differently, but VB max did not represent fully the true cutting edge of the deteriorating tool insert. Chipping and breakage of the inserts confined in the cutting edge area, resulting in the significant blunting of the edge, caused a high rate of F increase as VB max increased. Fracturing along the flank face of thin pieces effectively increased VB max without increasing the cutting edge area and without further blunting the edge, thus no increase in F was required. That the high rate, meaning high ΔFVB max , results from the effect of edge deterioration/blunting on reducing the effective rake angle and thus increasing F is suggested and discussed.

Keywords

Ni-superalloy Tool deterioration Cutting force Wear monitoring 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Zhu D, Zhang X, Ding H (2013) Tool wear characteristics in machining of nickel-based superalloys. Int J Mach Tools Manuf 64:60–77CrossRefGoogle Scholar
  2. 2.
    Pervaiz S, Rashid A, Deiab I, Nicolescu M (2014) Influence of tool materials on machinability of titanium and nickel-based alloys: a review. Mater Manuf Process 29:219–252CrossRefGoogle Scholar
  3. 3.
    Akhtar W, Sun J, Sun P, Chen W, Saleem Z (2014) Tool wear mechanisms in the machining of nickel based super-alloys: a review. Front Mech Eng 9:106–119CrossRefGoogle Scholar
  4. 4.
    Chinchanikar S, Choudhury SK (2015) Machining of hardened steel—experimental investigations, performance modeling and cooling techniques: a review. Int J Mach Tools Manuf 89:95–109CrossRefGoogle Scholar
  5. 5.
    Chen XQ, Li HZ (2009) Development of a tool wear observer model for online tool condition monitoring and control in machining nickel-based alloys. Int J Adv Manuf Technol 45:786–800CrossRefGoogle Scholar
  6. 6.
    Zhang S, Li JF, Wang YW (2012) Tool life and cutting forces in end milling Inconel 718 under dry minimum quantity cooling lubrication cutting conditions. J Clean Prod 32:81–87CrossRefGoogle Scholar
  7. 7.
    Ucun L, Aslantas K, Bedir F (2013) An experimental investigation of the effect of coating material on tool wear in micro milling of Inconel 718 super alloy. Wear 300:8–19CrossRefGoogle Scholar
  8. 8.
    Razak NH, Chen ZW, Pasang T (2014) Modes of tool deterioration during milling of 718Plus superalloy using cemented tungsten carbide tools. Wear 316:92–100CrossRefGoogle Scholar
  9. 9.
    Li HZ, Zeng H, Chen XQ (2006) An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts. J Mater Process Technol 18:296–304Google Scholar
  10. 10.
    Kasim MS, Che Haron CH, Ghani JA, Sulaiman MA, Yazid MZA (2013) Wear mechanism and notch wear location prediction model in ball nose end milling of Inconel 718. Wear 302:1171–1179CrossRefGoogle Scholar
  11. 11.
    Aramcharoen A, Chuan SK (2014) An experimental investigation on cryogenic milling of Inconel 718 and its sustainability assessment. Procedia CIRP 14:529–534CrossRefGoogle Scholar
  12. 12.
    Kong X, Yang L, Zhang H, Zhou K, Wang Y (2015) Cutting performance and coated tool wear mechanisms in laser-assisted milling K24 nickel-based superalloy. Int J Manuf Technol 77:2151–2163CrossRefGoogle Scholar
  13. 13.
    ISO 3002/4 (1984) International Organisation for Stardardization, GenevaGoogle Scholar
  14. 14.
    Kaya B, Oysu C, Ertunc HM (2011) Force-torque based on-line tool wear estimation system for CNC milling of Inconel 718 using neural networks. Adv Eng Softw 42:76–84CrossRefGoogle Scholar
  15. 15.
    Nouri M, Fussell BK, Zinit BL, Linder E (2015) Real-time tool wear monitoring in milling using a cutting condition independent method. Int J Mach Tool Manuf 89:1–13CrossRefGoogle Scholar
  16. 16.
    Lauro CH, Brandão LC, Baldo D, Reis RA, Davim JP (2014) Monitoring and processing signal applied in machining processes—a review. Measurement 58:73–86CrossRefGoogle Scholar
  17. 17.
    Sharman A, Dewes RC, Aspinwall DK (2001) Tool life when high speed ball nose end milling Inconel 718. J Mater Process Technol 118:29–35CrossRefGoogle Scholar
  18. 18.
    Devillez A, Le Coz G, Dominiak S, Dudzinski D (2011) Dry machining of Inconel 718, workpiece surface integrity. J Mater Process Technol 211:1590–1598CrossRefGoogle Scholar
  19. 19.
    Kadirgama K, Abou-El-Hossein KA, Noor MM, Sharma KV, Mohammad B (2011) Tool life and wear mechanism when machining Hastelloy C-22HS. Wear 270:258–268CrossRefGoogle Scholar
  20. 20.
    Henderson AJ (2012) Updated force model for milling nickel-based superalloys. PhD thesis, Clemson UniversityGoogle Scholar
  21. 21.
    Navas VG, Arriola I, Gonzalo O, Leunda J (2013) Mechanisms involved in the improvement of Inconel 718 machinability by laser assisted machining (LAM). Int J Mach Tools Manuf 74:19–28CrossRefGoogle Scholar
  22. 22.
    ISO 8688–2 (1989) International Organisation for Stardardization, GenevaGoogle Scholar
  23. 23.
    Wang X, Huang C, Zou B, Liu H, Zhu H, Wang J (2014) A new method to evaluate the machinability of difficult-to-cut materials. Int J Adv Manuf Technol 75:91–96CrossRefGoogle Scholar
  24. 24.
    Denkena B, Biermann D (2014) Cutting edge geometries. Cut Ann Manuf Technol 63:631–653CrossRefGoogle Scholar
  25. 25.
    Grzesik W (2008) Chapter 6: Orthogonal and oblique cutting mechanics in Advanced Machining Processes of Metallic Materials - Theory, Modelling and Applications. Elsevier Science: 69–84Google Scholar
  26. 26.
    Fleisher J, Schelze V, Kotschenrenther J (2009) Extension of cutting force formulae for microcutting. J CIRP Ann J Manuf Sci Technol 2:75–80CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2016

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringAuckland University of TechnologyAucklandNew Zealand

Personalised recommendations