Effect of Machining Parameters on Surface Integrity in Machining Nimonic C-263 Super Alloy Using Whisker-Reinforced Ceramic Insert

  • C. Ezilarasan
  • V. S. Senthil kumar
  • A. Velayudham


Whisker-reinforced ceramic inserts were used to conduct turning trials on nimonic C-263 super alloy to study the effect of different combinations of cutting parameters on surface integrity (roughness, microhardness, and residual stress) by employing energy dispersive spectroscopy, scanning electron microscopy, x-ray diffraction, and Vicker’s microhardness test. Abrasion, adhesion and diffusion were found to be the main tool wear mechanisms in turning nimonic C-263 alloy. Based on characterization of surface roughness, a combination of 190 m/min cutting speed and 0.102 mm/rev feed rate was found to be the critical condition for turning nimonic C-263 alloy. Microhardness varied between 550 and 690 HV at the feed rates of 0.102-0.143 mm/rev for a cutting speed of 250 m/min after 9 min of turning. A tensile residual stress of 725-850 MPa on the machined surface was recorded at the preceding combination of cutting parameters. Cutting speed and cutting time had a dominant effect on the magnitude of the residual stress. No evidence of thermal relaxation and reduction in the degree of work hardening was noted during machining at high cutting speed.


cutting force microhardness nimonic C-263 residual stresses surface finish surface integrity tool wear turning 


  1. 1.
    J.C. Outeiro, J.C. Pina, R. M’Saoubi, F. Pusavec, and I.S. Jawahir, Analysis of Residual Stresses Induced by Dry Turning of Difficult-to-Machine Materials, CIRP Ann. Manuf. Technol., 2008, 57, p 77–80CrossRefGoogle Scholar
  2. 2.
    I.A. Choudhury and M.A. El-Baradi, Machinability of Nickel-Base Super Alloys: A General Review, J. Mater. Process. Technol., 1998, 77, p 278–284CrossRefGoogle Scholar
  3. 3.
    J. Vigneau and J.J. Boulanger, Behaviour of Ceramic Tools During the Machining of Nickel Base Alloys, Ann. CIRP, 1982, 31, p 35–39CrossRefGoogle Scholar
  4. 4.
    A. Gatto and L. Iuliano, Advanced Coated Ceramic Tools for Machining Super Alloys, Int. J. Mach. Tools Manuf., 1997, 37, p 591–605CrossRefGoogle Scholar
  5. 5.
    L. Li, N. He, M. Wang, and Z.G. Wang, High Speed Cutting of Inconel 718 With Coated Carbide and Ceramic Inserts, J. Mater. Process. Technol., 2002, 129(1–3), p 127–130CrossRefGoogle Scholar
  6. 6.
    A. Chakraborty, K.K. Ray, and S.B. Bhaduri, Comparative Wear Behavior of Ceramic and Carbide Tools during High speed Machining of Steel, Mater. Manuf. Process. doi:  10.1080/10426910008912988
  7. 7.
    T. Kitagawa, A. Kubo, and K. Maekawa, Temperature and Wear of Cutting Tools in High-Speed Machining of Inconel 718 and Ti-6Al-6V-2Sn, Wear, 1997, 202, p 142–148CrossRefGoogle Scholar
  8. 8.
    D.G. Thakur, B. Ramamoorthy, and L. Vijayaraghavan, An Experimental Analysis of Effective High Speed Turning of Super Alloy Inconel 718, J. Mater. Sci., 2009, 44, p 3296–3304CrossRefGoogle Scholar
  9. 9.
    D.G. Thakur, B. Ramamoorthy, and L. Vijayaraghavan, Study on the Machinability Characteristics of Super Alloy Inconel 718 During High Speed Turning, Mater. Des., 2009, 30, p 1718–1725CrossRefGoogle Scholar
  10. 10.
    E.O. Ezugwu and C.I. Okeke, Performance of PVD Coated Carbide Inserts When Machining Nimonic C-263 Alloy at High Speed Conditions, Tribol. Trans., 2000, 43, p 332–336CrossRefGoogle Scholar
  11. 11.
    E.O. Ezugwu, A. Jawaid. The Effect of Coatings on the Performance of Carbide Cutting Tools When Machining Nickel Base, Inconel 718, Superalloy, Proceedings of the 5th International Manufacturing Conference in China, 1991, p A268–A296Google Scholar
  12. 12.
    J. Aucote and S.R. Foster, Performance of Sialon Cutting Tools When Machining Nickel Base Aerospace Alloys, Mater. Sci. Technol., 1986, 2, p 700–708Google Scholar
  13. 13.
    A.M. El-Tamimi and T.M. Ei-Hossainy, Investigating the Tool Life, Cutting Force Components, and Surface Roughness of AISI, 302 Stainless Steel Material Under Oblique Machining, Mater. Manuf. Processes, 2008, 23, p 427–438CrossRefGoogle Scholar
  14. 14.
    W. Li, P.J. Withers, D. Axinte, M. Preuss, and P. Andrews, Residual Stresses in Face Finish Turning of High Strength Nickel-Based Super Alloy, J. Mater. Process. Technol., 2009, 209, p 4896–4902CrossRefGoogle Scholar
  15. 15.
    R.M. Arunachalam, M.A. Mannan, and A.C. Spewage, Residual Stress and Surface Roughness When Facing Age Hardened Inconel 718 with CBN and Ceramic Cutting Tools, Mach. Tools Manuf., 2004, 44, p 879–887CrossRefGoogle Scholar
  16. 16.
    T. Berruti, M. Lavella, and M.M. Gola, Residual Stresses on Inconel 718 Turbine Shaft Samples After Turning, Mach. Sci. Technol., 2009, 13, p 543–560CrossRefGoogle Scholar
  17. 17.
    D. Ulutana and T. Ozel, Machining Induced Surface Integrity in Titanium and Nickel Alloys: A Review, Int. J. Mach. Tools Manuf., 2011, 51, p 250–280CrossRefGoogle Scholar
  18. 18.
    S.C. Veldhuis, G.K. Dosbaeva, A. Elfizy, G.S. Fox-Rabinovich, and T. Wagg, Investigations of White Layer Formation During Machining of Powder Metallurgical Ni-Based ME 16 Superalloy, J. Mater. Eng. Perform., 2010, 19, p 1031–1036CrossRefGoogle Scholar
  19. 19.
    M.C. Shaw, Metal Cutting Principles, 2nd ed., Oxford University Press, New York, 2005, p 432–454Google Scholar
  20. 20.
    K. Ankamma, D.V.V. Satyanarayana, G. Chandramohan Reddy, M. Komaraiah, and N. Eswara Prasad, In-Plane Anisotropy in Tensile Deformation and Its Influence on the Drawability of Nimonic C-263 Alloy Sheets, Sādhanā, 2011, 36, p 223–249Google Scholar
  21. 21.
    Y.B. Guo, W. Li, and I.S. Jawahir, Surface Integrity Characterization and Prediction in Machining of Hardened and Difficult-to-Machine Alloys; A State-of-the-Art Research Review and Analysis, Mach. Sci. Technol., 2009, 13, p 437–470CrossRefGoogle Scholar

Copyright information

© ASM International 2012

Authors and Affiliations

  • C. Ezilarasan
    • 1
  • V. S. Senthil kumar
    • 1
  • A. Velayudham
    • 2
  1. 1.Department of Mechanical EngineeringAnna UniversityChennaiIndia
  2. 2.CVRDEChennaiIndia

Personalised recommendations