Effect of machining parameters on cutting force and surface integrity when high-speed turning AD 730™ with PCBN tools
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The novel wrought nickel-based superalloy, AD 730™, is a good candidate material for turbine disc applications at high temperatures beyond 650 °C. The present study focuses on the machining performance of this newly developed alloy under high-speed turning conditions with advanced PCBN tools. Meanwhile, the machined surface integrity as influenced by cutting speed and feed rate was also investigated. The surface integrity was thoroughly characterized in terms of surface roughness and morphology, machining-induced plastic deformation, white layer formation, and residual stresses. It has been found that the cutting speed and feed rate had a strong effect on the cutting forces and resultant surface integrity. The cutting forces required when machining the alloy were gradually reduced with increasing cutting speed, while at 250 m/min and above, the flank tool wear became stronger which led to increased thrust force and feed force. A higher feed rate, on the other hand, always resulted in higher cutting forces. Increasing the cutting speed and feed rate in general deteriorated the surface integrity. High cutting speeds within the range of 200–250 m/min and a low feed rate of 0.1 mm/rev are preferable in order to implement more cost-effective machining without largely reducing the surface quality achieved. The formation of tensile residual stresses on the machined AD 730™, however, could be of a concern where good fatigue resistance is critical.
KeywordsNickel-based superalloy High-speed turning Cutting forces Surface integrity AD 730™ Cubic boron nitride (CBN) tool
The research project is carried out within the framework of the strategic innovation program “Metallic Materials,” a joint program of Vinnova, Formas, and Energy Agency of Sweden. The authors would like to express great acknowledgements to the funding agencies for the financial support and to Siemens Industrial Turbomachinery AB, Seco Tools AB, and Aubert & Duval for their supports with materials and cutting tools. In addition, Mr. P. Almroth, Mr. F. Palmert, Mr. P. Jonander, and Mr. J. Eriksson are acknowledged as well for their valuable contributions to this work from the industrial perspectives.
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