Advertisement

An investigation of the effect of a new tool treatment technique on the machinability of Inconel 718 during the turning process

  • Saharnaz MontazeriEmail author
  • Maryam Aramesh
  • Stephen C. Veldhuis
ORIGINAL ARTICLE
  • 111 Downloads

Abstract

Though Inconel 718 alloy possesses excellent material properties and has various key applications in different industries, it still suffers from severe machinability issues and is considered one of the most difficult-to-cut materials. In this paper, a new and simple method is proposed to improve the machinability of Inconel 718 by forming different ductile and lubricious layers at the tool tip prior to its application for machining. Previous research showed that this method is very successful at improving the tool performance. In the current study, an enhancement of the proposed method is presented. Prior to the actual machining of Inconel, very short cuts of around two seconds were performed on an Al-Si and/or cast iron workpiece to form very thin layers of these materials on the tool rake face. During the subsequent machining of Inconel, the built-up material on the tool face has melted and the excess material was pushed out of the contact zone, with just a thin film remaining on the tool. This thin film protected the tool from chipping and considerably improved the tool life and the integrity of the machined surface. Results indicate that the tool treated with both cast iron and aluminum possessed a maximum tool life increase of 204%, a 45% lesser cutting force, and a 59% reduction in machining-induced work-hardening compared to the uncoated tool. All of the treatments displayed significantly reduced chipping. The following mechanisms contributed to these improvements: filling of the tool microcracks and prevention of their propagation, friction reduction enabling greater control over adhesion, seizure and built-up edge formation, improvement of the running-in stage of tool wear by preconditioning the tool surface prior to its main application, formation of various lubricious and thermal barrier tribofilms on the tool tip, control of different tool wear mechanisms such as adhesion, abrasion, and oxidation. All these mechanisms are discussed in details using various characterization techniques.

Keywords

Inconel 718 Tool treatment Tool wear Work-hardening 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Acknowledgments

The authors would like to also thank Dr. Cavelli for performing the XPS studies and Dr. Bose for performing the nano-wear and nano-indentation tests.

Funding information

This research was supported by the Natural Sciences and Engineering Research Council of Canada (NSERC) under the CANRIMT Strategic Research Network Grant NETGP 479639-15.

References

  1. 1.
    Thakur DG, Ramamoorthy B, Vijayaraghavan L (2009) Machinability investigation of Inconel 718 in high-speed turning. Int J Adv Manuf Technol 45(5–6):421–429CrossRefGoogle Scholar
  2. 2.
    Hua Y, Liu Z (2018) Effects of cutting parameters and tool nose radius on surface roughness and work hardening during dry turning Inconel 718. Int J Adv Manuf Technol 96(5–8):2421–2430CrossRefGoogle Scholar
  3. 3.
    Thakur A, Gangopadhyay S (2016) State-of-the-art in surface integrity in machining of nickel-based super alloys. Int J Mach Tools Manuf 100:25–54CrossRefGoogle Scholar
  4. 4.
    M'Saoubi R, Axinte D, Soo SL, Nobel C, Attia H, Kappmeyer G, Engin S, Sim WM (2015) High performance cutting of advanced aerospace alloys and composite materials. CIRP Ann - Manuf Technol 64(2):557–580Google Scholar
  5. 5.
    Fox-Rabinovich GS, Beake BD, Yamamoto K, Aguirre MH, Veldhuis SC, Dosbaeva G, Elfizy A, Biksa A, Shuster LS (2010) Structure, properties and wear performance of nano-multilayered TiAlCrSiYN/TiAlCrN coatings during machining of Ni-based aerospace superalloys. Surf Coat Technol 204(21–22):3698–3706CrossRefGoogle Scholar
  6. 6.
    Thakur DG, Ramamoorthy B, Vijayaraghavan L (2009) Study on the machinability characteristics of superalloy Inconel 718 during high speed turning. Mater Des 30(5):1718–1725CrossRefGoogle Scholar
  7. 7.
    Thakur DG, Ramamoorthy B, Vijayaraghavan L (2012) Some investigations on high speed dry machining of aerospace material Inconel 718 using multicoated carbide inserts. Mater Manuf Process 27(10):1066–1072CrossRefGoogle Scholar
  8. 8.
    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(2):106–119CrossRefGoogle Scholar
  9. 9.
    Kitagawa T, Kubo A, Maekawa K (1997) Temperature and wear of cutting tools in high-speed machining of Inconel 718 and Ti6Al6V2Sn. Wear 202(2):142–148CrossRefGoogle Scholar
  10. 10.
    Garcia-gonzalez JC, Moscoso-kingsley W, Madhavan V (2016) Tool Rake Face Temperature Distribution when Machining Ti6Al4V and Inconel 718. Procedia Manuf 5:1369–1381Google Scholar
  11. 11.
    Addona DMD, Raykar SJ, Narke MM (2017) High speed machining of Inconel 718: tool wear and surface roughness analysis. Procedia CIRP 62:269–274CrossRefGoogle Scholar
  12. 12.
    Shinde SN, Vankudre HV,Thakur DG (2016) A comparative study of cutting force, feed force, surface roughness and tool wear in machining of Inconel 718 with uncoated and coated tungsten carbide inserts. Int. J Appl Sci Eng Res 5(1):30–38Google Scholar
  13. 13.
    Yılmaz B, Karabulut Ş, Güllü A (2018) Performance analysis of new external chip breaker for efficient machining of Inconel 718 and optimization of the cutting parameters. J Manuf Process 553–563Google Scholar
  14. 14.
    Manohar AXMM, Jeyapandia rajan P, Madhukar PM (2017) Tool wear assessment during machining of Inconel 718. Procedia Eng 174:1000–1008CrossRefGoogle Scholar
  15. 15.
    Dudzinski D, Devillez A, Moufki A, Larrouquère D, Zerrouki V, Vigneau J (2004) A review of developments towards dry and high speed machining of Inconel 718 alloy. Int J Mach Tools Manuf 44(4):439–456CrossRefGoogle Scholar
  16. 16.
    Dosbaeva GK, Veldhuis SC, Yamamoto K, Wilkinson DS, Beake BD, Jenkins N, Elfizy A, Fox-Rabinovich GS (2010) Oxide scales formation in nano-crystalline TiAlCrSiYN PVD coatings at elevated temperature. Int J Refract Met Hard Mater 28(1):133–141CrossRefGoogle Scholar
  17. 17.
    Caliskan H, Kursuncu B, Guven SY, Karaoglanli AC, Sabri Gok M, Alsaran A (2016) Effect of boron nitride coating on wear behavior of carbide cutting tools in milling of Inconel 718. Springer, Singapore, pp 13–21Google Scholar
  18. 18.
    Khan SA, Soo SL, Aspinwall DK, Sage C, Harden P, Fleming M, White A, M'Saoubi R (2012) Tool wear/life evaluation when finish turning Inconel 718 using PCBN tooling. Procedia CIRP 1:283–288Google Scholar
  19. 19.
    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
  20. 20.
    Sugihara T, Tanaka H, Enomoto T (2017) Development of novel CBN cutting tool for high speed machining of Inconel 718 focusing on coolant behaviors. Procedia Manuf 10:436–442CrossRefGoogle Scholar
  21. 21.
    Behera BC, Alemayehu H, Ghosh S, Rao PV (2017) A comparative study of recent lubri-coolant strategies for turning of Ni-based superalloy. J Manuf Process 30:541–552CrossRefGoogle Scholar
  22. 22.
    Yuan J, Yamamoto K, Covelli D, Tauhiduzzaman M, Arif T, Gershman IS, Veldhuis SC, Fox-Rabinovich GS (2016) Tribo-films control in adaptive TiAlCrSiYN/TiAlCrN multilayer PVD coating by accelerating the initial machining conditions. Surf Coat Technol 294:54–61CrossRefGoogle Scholar
  23. 23.
    Aramesh M, Montazeri S, Veldhuis SC (2018) A novel treatment for cutting tools for reducing the chipping and improving tool life during machining of Inconel 718. Wear 414–415:79–88CrossRefGoogle Scholar
  24. 24.
    Krook M, Recina V, Karlsson B (2005) Material properties affecting the machinability of Inconel 718, Superalloys 718, 625, 706 Var. Deriv., 613–627Google Scholar
  25. 25.
    Thakur DG, Ramamoorthy B, Vijayaraghavan L (2012) Effect of cutting parameters on the degree of work hardening and tool life during high-speed machining of Inconel 718. Int J Adv Manuf Technol 59(5–8):483–489Google Scholar
  26. 26.
    Zamani M (2017) Al-Si Cast Alloys-Microstructure and Mechanical Properties at Ambient and Elevated Temperatures. Jönköping University, School of EngineeringGoogle Scholar
  27. 27.
    Abedi HR, Fareghi A, Saghafian H, Kheirandish SH (2010) Sliding wear behavior of a ferritic – pearlitic ductile cast iron with different nodule count. Wear 268(3–4):622–628CrossRefGoogle Scholar
  28. 28.
    Sequoia E, Sugishita J (1981) The effect of cast iron graphites on friction and wear performance: II: variables influencing graphite film formation. Wear 68(1):7–20Google Scholar
  29. 29.
    Devillez A, Schneider F, Dominiak S, Dudzinski D, Larrouquere D (2007) Cutting forces and wear in dry machining of Inconel 718 with coated carbide tools. Wear 262(7–8):931–942CrossRefGoogle Scholar
  30. 30.
    Thellaputta GR, Chandra PS, Rao CSP (2017) Machinability of nickel based superalloys: a review. Mater Today Proc 4(2):3712–3721CrossRefGoogle Scholar
  31. 31.
    Keller BP, Nelson SE, Walton KL, Ghosh TK, Tompson RV, Loyalka SK (2015) Total hemispherical emissivity of Inconel 718. Nucl Eng Des 287:11–18CrossRefGoogle Scholar
  32. 32.
    Zhang S, Li JF, Wang YW (2012) Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions. J Clean Prod 32:81–87Google Scholar
  33. 33.
    Duong X, Mayer JRR, Balazinski M (2016) Initial tool wear behavior during machining of titanium metal matrix composite ( TiMMCs ). Int J Refract Met Hard Mater 60:169–176CrossRefGoogle Scholar
  34. 34.
    Tripathi K, Gyawali G, Lee SW (2017) Graphene coating via chemical vapor deposition for improving friction and wear of gray cast iron at interfaces. ACS Appl Mater Interfaces 9(37):32336–32351Google Scholar
  35. 35.
    Bhatt A, Attia H, Vargas R, Thomson V (2010) Wear mechanisms of WC coated and uncoated tools in finish turning of Inconel 718. Tribiol Int 43(5–6):1113–1121CrossRefGoogle Scholar
  36. 36.
    Ghani JA, Che Haron CH, Kasim MS, Sulaiman MA, Tomadi SH (2016) Wear mechanism of coated and uncoated carbide cutting tool in machining process. J. Mater. Res. 31(13):1873–1879Google Scholar
  37. 37.
    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
  38. 38.
    Hao Z, Gao D, Fan Y, Han R (2011) New observations on tool wear mechanism in dry machining Inconel718. Int J Mach Tools Manuf 51(12):973–979CrossRefGoogle Scholar
  39. 39.
    Ren X, Liu Z (2016) Influence of cutting parameters on work hardening behavior of surface layer during turning superalloy Inconel 718. Int J Adv Manuf Technol 86(5–8):2319–2327CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Saharnaz Montazeri
    • 1
    Email author
  • Maryam Aramesh
    • 1
  • Stephen C. Veldhuis
    • 1
  1. 1.McMaster Manufacturing Research Institute (MMRI), Department of Mechanical EngineeringMcMaster UniversityHamiltonCanada

Personalised recommendations