Abstract
High-pressure cooling has proven to be very effective when machining with carbide inserts. Longer tool life and improved chip breaking are among the most commonly mentioned advantages. Nevertheless, this cooling method has been reported to reduce the life of ceramic tools in machining of heat-resistant alloys. The main reason for that is said to be the accelerated notch wear. Therefore, in this study, SiAlON ceramic inserts with improved resistance to notching were tested in machining of Inconel 718 under high-pressure cooling. The results were compared to conventional cooling. It turned out that, while notch wear was still slightly increased when high-pressure cooling was applied, it was no longer critical for the tool life. Flank wear, on the other hand, was reduced, which led to significantly longer tool life. The variation of the tool life appeared to be slightly less and chip breaking was considerably improved. This shows that, when used properly, high-pressure cooling can help to increase the productivity in machining of heat-resistant alloys with ceramic tools.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Narutaki N, Yamane Y, Hayashi K, Kitagawa T, Uehara K (1993) High-speed machining of Inconel 718 with ceramic tools. CIRP Annals—Manufacturing Technology 42(1):103–106
Kitagawa T, Kubo A, Maekawa K (1997) Temperature and wear of cutting tools in high-speed machining of Inconel 718 and Ti–6Al–6V–2Sn. Wear 202(2):142–148
Vigneau J, Boulanger J, Le Maitre F (1982) Behaviour of ceramic tools during the machining of nickel base alloys. CIRP Annals—Manufacturing Technology 31(1):35–39
Boothroyd G, Knight WA (2006) Fundamentals of machining and machine tools. Taylor & Francis, Boca Raton
Li L, He N, Wang M, Wang ZG (2002) High speed cutting of Inconel 718 with coated carbide and ceramic inserts. J Mater Process Technol 129(1–3):127–130
Klocke F, Eisenblätter G (1997) Dry cutting. CIRP Annals—Manufacturing Technology 46(2):519–526
Pigott R, Colwell A (1952) Hi-jet system for increasing tool life. Society of Automotive Engineers—Transactions 6(3):547–564
Ezugwu EO, Machado AR, Pashby IR, Wallbank J (1991) The effect of high-pressure coolant supply when machining a heat-resistant nickel-based superalloy. Lubr Eng 47(9):751–757
Kalpakjian S, Schmid SR (2006) Manufacturing engineering and technology. Prentice Hall, Singapore
Sharma CS, Rice WB, Salmon R (1971) Some effects of injecting cutting fluids directly into the chip-tool interface. J Eng Ind, Transactions of the ASME 93:441–444
Mazurkiewicz M, Kubala Z, Chow J (1989) Metal machining with high-pressure water-jet cooling assistance—a new possibility. J Eng Ind, Transactions of the ASME 111:7–12
Nagpal BK, Sharma CS (1973) Cutting fluids performance—Part 1—Optimization of pressure for “Hi-jet” method of cutting fluid application. J Eng Ind, Transactions of the ASME 95:881–889
Kovacevic R, Cherukuthota C, Mohan R (1995a) Improving milling performance with high pressure waterjet assisted cooling/lubrication. J Eng Ind 117(3):331–339
Kovacevic R, Cherukuthota C, Mazurkiewicz M (1995b) High pressure waterjet cooling/lubrication to improve machining efficiency in milling. Int J Mach Tools Manuf 35(10):1459–1473
Ezugwu EO, Bonney J (2005) Finish machining of nickel-base Inconel 718 alloy with coated carbide tool under conventional and high-pressure coolant supplies. Tribol Trans 48(1):76–81
Nandy A, Gowrishankar M, Paul S (2009) Some studies on high-pressure cooling in turning of Ti–6Al–4V. Int J Mach Tools Manuf 49(2):182–198
Senthil Kumar A, Rahman M, Ng SL (2002) Effect of high-pressure coolant on machining performance. Int J Adv Manuf Technol 20(2):83–91
Ezugwu EO, Bonney J (2004) Effect of high-pressure coolant supply when machining nickel-base, Inconel 718, alloy with coated carbide tools. J Mater Process Technol 153–154:1045–1050
Sharman A, Hughes J, Ridgway K (2008) Surface integrity and tool life when turning Inconel 718 using ultra-high pressure and flood coolant systems. Proc Inst Mech Eng, B J Eng Manuf 222(6):653–664
Kaminski J, Alvelid B (2000) Temperature reduction in the cutting zone in water-jet assisted turning. J Mater Process Technol 106(1–3):68–73
Wertheim R, Rotberg J, Ber A (1992) Influence of high-pressure flushing through the rake face of the cutting tool. CIRP Annals—Manufacturing Technology 41(1):101–106
Sørby K, Bjørnstad MS, Tønnessen K (2006) The effect of high-pressure cutting fluid on chip breaking and tool life in turning of nickel-base alloys. In: CIRP 2nd International Conference on High Performance Cutting, Vancouver, 12–13 June 20006
Sørby K, Tønnessen K (2006) High-pressure cooling of face-grooving operations in Ti6Al4V. Proc Inst Mech Eng, B J Eng Manuf 220(B10):1621–1627
Machado AR, Wallbank J, Pashby I, Ezugwu EO (1998) Tool performance and chip control when machining Ti6Al4V and Inconel 901 using high pressure coolant supply. Mach Sci Technol 2(1):1–12
Nandy A, Paul S (2008) Effect of coolant pressure, nozzle diameter, impingement angle and spot distance in high pressure cooling with neat oil in turning Ti–6Al–4V. Mach Sci Technol 12(4):445–473
Ezugwu EO, Bonney J, Da Silva RB, Machado AR, Ugwoha E (2009) High productivity rough turning of Ti–6Al–4V alloy, with flood and high-pressure cooling. Tribol Trans 52(3):395–400
Kramar D, Krajnik P, Kopac J (2010) Capability of high pressure cooling in the turning of surface hardened piston rods. J Mater Process Technol 210(2):212–218
Sadik MI, Lindström B (1995) The effect of restricted contact length on tool performance. J Mater Process Technol 48(1–4):275–282
Ezugwu EO, Bonney J (2003) Effect of high-pressure coolant supplies when machining nickel-base, Inconel 718, alloy with ceramic tools. Tribol Trans 46(4):580–584
Ezugwu EO, Bonney J, Fadare D, Sales W (2005) Machining of nickel-base, Inconel 718, alloy with ceramic tools under finishing conditions with various coolant supply pressures. J Mater Process Technol 162–163:609–614
Öjmertz K, Oskarson HB (1999) Wear on SiC-whiskers reinforced ceramic inserts when cutting Inconel with waterjet assistance. Tribol Trans 42(3):471–478
Wager JG, Barash MM (1971) Study of the distribution of the life of HSS tools. J Eng Ind, Transactions of the ASME 93:1044–1050
Wiklund H (1998) Bayesian and regression approaches to on-line prediction of residual tool life. Qual Reliab Eng Int 14(5):303–309
ISO 3685 (1993) Tool-life testing with single-point turning tools. International Organization for Standardization, Geneva
Zhou C, Wysk RA (1992) Integrated system for selecting optimum cutting speeds and tool replacement times. Int J Mach Tools Manuf 32(5):695–707
Kwon WT, Park JS, Kang S (2005) Effect of group IV elements on the cutting characteristics of Ti(C,N) cermet tools and reliability analysis. J Mater Process Technol 166(1):9–14
Dašić P, Natsis A, Petropoulos G (2008) Models of reliability for cutting tools: examples in manufacturing and agricultural engineering. Strojniški Vestnik—Journal of Mechanical Engineering 54(2):122–130
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This is an open access article distributed under the terms of the Creative Commons Attribution Noncommercial License (https://creativecommons.org/licenses/by-nc/2.0), which permits any noncommercial use, distribution, and reproduction in any medium, provided the original author(s) and source are credited.
About this article
Cite this article
Vagnorius, Z., Sørby, K. Effect of high-pressure cooling on life of SiAlON tools in machining of Inconel 718. Int J Adv Manuf Technol 54, 83–92 (2011). https://doi.org/10.1007/s00170-010-2944-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-010-2944-4