Abstract
Surface integrity (SI) and, particularly, the residual stress profile, has a great influence on the fatigue life of machined aeronautical critical parts. Among the different cutting parameters that affect the final SI, tool geometry is one of the most important factors. In particular, tool nose radius determines the surface roughness, as well as the thermoplastic deformation of the workpiece. Indeed, the use of large tool nose radius in the industry enables (1) increasing the feed rate while keeping the roughness values below specifications and (2) reducing the influence of the tool wear in the surface roughness. Therefore, in this study, the influence of tool nose radius in the induced residual stress profile and work-hardened layer when face turning Inconel 718 is analysed for a cutting speed range between (30–70 m/min) and a feed rate range of (0.15–0.25 mm/rev). For this purpose, residual stress profiles and work-hardened layer were measured by x-ray diffraction method after machining with a 4 mm nose radius. Then, results have been compared against different tool nose radius studies carried out by other authors for the specified working conditions. Results revealed that residual stress profiles varied when machining with different nose radius for the studied range. In particular, the increase of the nose radius brought to a higher difference between surface tensile stress and subsurface compressive peak stress, which is attributed to an increase of the thermal effect. Moreover, thicker work-hardened layer (around 100 μm) was observed when machining with large-nose radius for the studied working conditions.
Similar content being viewed by others
References
Winstone MR, Brooks JW (2008) Advanced high temperature materials: aeroengine fatigue. Cienc Tecnol Mater 20(1):15–24
Ezugwu EO (2004) High speed machining of aero-engine alloys. J Braz Soc Mech Sci Eng 26(1):1–11. doi:10.1590/S1678-58782004000100001
Miller S (1996) Advanced materials mean advanced engines. Interdiscip Sci Rev 21(2):117–129. doi:10.1179/030801896789845671
Thakur DG, Ramamoorthy L, Vijayaraghavan L (2009) Machinability investigation of Inconel 718 in high-speed turning. Int J Adv Manuf Technol 45:421–429. doi:10.1007/s00170-009-1987-x
Wallbrink C, Weiping Hu (2010) A strain-life module for CGAP: theory, user guide and examples (No. DSTO-TR-2392). Def Sci Technol Organ Vic (Aust) Air Div
M’Saoubi R, Outeiro JC, Changeux B, Lebrun JL, Dias AM (1999) Residual stress analysis in orthogonal machining of standard and resulfurized AISI 316L steels. J Mater Process Technol 96(1):225–233. doi:10.1016/S0924-0136(99)00359-3
Whiters PJ, Bhadeshia HKDH (2001) Residual stress. Part 1—measurement techniques. Mater Sci Technol 17(4):355–364. doi:10.1179/026708301101509980
M’Saoubi R, Outeiro JC, Chandrasekaran H, Dillon OW Jr, Jawahir IS (2008) A review of surface integrity in machining and its impact on functional performance and life of machined products. Int J Sustain Manuf 1(1):203–236. doi:10.1504/IJSM.2008.019234
Guo YB, Li W, Jawahir IS (2009) Surface integrity characterization and prediction in machining of hardened and difficult-to-machine alloys: a state-of-art research review and analysis. Mach Sci Technol 13(4):437–470. doi:10.1080/10910340903454922
Jawahir IS, Brinksmeier E, M’Saoubi R, Aspinwall DK, Outeiro JC, Meyer D, Umbrello D, Jayal AD (2011) Surface integrity in material removal processes: recent advances. CIRP Ann-Manuf Technol 60(2):603–626. doi:10.1016/j.cirp.2011.05.002
Berruti T, Lavella M, Gola MM (2009) Residual stresses on Inconel 718 turbine shaft after turning. Mach Sci Technol 13(4):543–560. doi:10.1080/10910340903451472
Sadat AB, Reddy MY (1992) Surface integrity of inconel-718 nickel-base superalloy using controlled and natural contact length tools part I: lubricated. Exp Mech 32(3):282–288. doi:10.1007/BF02319367
Schlauer C, Peng RL, Odén M (2002) Residual stresses in a nickel-based superalloy introduced by turning. Mater Sci Forum 404–407:173–178. doi:10.4028/www.scientific.net/MSF.404-407.173
Arunachalam RM, Mannan MA (2003) Surface finish and residual stresses in facing of age hardened INCONEL 718. Mater Sci Forum 437–438:503–506. doi:10.4028/www.scientific.net/MSF.437-438.503
Sharman ARC, Hughes JI, Ridgway K (2006) An analysis of the residual stresses generated in Inconel 718 when turning. J Mater Process Technol 173(3):359–367. doi:10.1016/j.jmatprotec.2005.12.007
Pawade RS, Joshi SS, Brahmankar PK (2008) Effect of machining parameters and cutting edge geometry on surface integrity of high-speed turned Inconel 718. Int J Mach Tools Manuf 48(1):15–28. doi:10.1016/j.ijmachtools.2007.08.004
Arunachalam RM, Mannan MA, Spowage AC (2004) Residual stress and surface roughness when facing age hardened inconel 718 with CBN and ceramic cutting tools. Int J Mach Tools Manuf 44(9):879–887. doi:10.1016/j.ijmachtools.2004.02.016
Coelho RT, Silva LR, Braghini A, Bezerra AA (2004) Some effects of cutting edge preparation and geometric modifications when turning INCONEL 718TM at high cutting speed. J Mater Process Technol 148(1):147–153. doi:10.1016/j.jmatprotec.2004.02.001
Sharman ARC, Hughes JI, Ridgway K (2004) Workpiece surface integrity and tool life issues when turning Inconel 718TM nickel based superalloy. J Mach Sci Technol 8(3):399–414. doi:10.1081/MST-200039865
Thakur DG, Ramamoorthy L, 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 59:483–489. doi:10.1007/s00170-011-3529-6
Ezugwu EO, Wang ZM, Okeke CI (1999) Tool life and surface integrity when machining Inconel 718 with PVD- and CVD-coated tool. Tribol Trans 42(2):353–360. doi:10.1080/10402009908982228
Dogra M, Sharma VS, Dureja J (2011) Effect of tool geometry variation on finish turning. J Eng Sci Technol Rev 4:1–13
Liu M, Takagi J, Tsukuda A (2004) Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel. J Mater Process Technol 150(3):234–241. doi:10.1016/j.jmatprotec.2004.02.038
Outeiro JC, Pina JC, M’Saoubi R, Pusavec F, Jawahir IS (2008) Analysis of residual stresses induced by dry turning of difficult-to-machine materials. CIRP Ann-Manuf Technol 57(1):77–80. doi:10.1016/j.cirp.2008.03.076
François M, Sprauel JM, Déhan CF, James MR, Convert F, Lu J, Lebrun JL, Ji N, Hendricks RW (1996) X-ray diffraction method. In: Lu J (ed) Handbook of measurement of residual stresses. The Fairmont Press, Inc, Lilburn, pp 71–131
Prevéy PS (1987) The measurement of subsurface residual stress and cold work distributions in nickel base alloys. Residual Stress in Design, Process & Materials Selections, ed. WB Young, Metals Park, OH: Am. Soc. For Metals, pp 11–19
Hoffmeister J, Schulze V, Hessert R, Koenig G (2012) Residual stresses under quasi-static and cyclic loading in shot peened Inconel 718. Int J Mater Res 103(1):66–72
Fang N, Srinivasa Pai P, Edwards N (2013) A comparative study of high-speed machining of Ti-6Al-4V and Inconel 718-part I: effect of dynamic tool edge wear on cutting forces. Int J Adv Manuf Technol. doi:10.1007/s00170-013-4981-2
Grant P, Lord J, Whitehead P, Fry T (2005) The application of fine increment hole drilling for measuring machining-induced residual stresses. Appl Mech Mater 3–4:105–110. doi:10.4028/www.scientific.net/AMM.3-4.105
García Navas V, Gonzalo O, Bengoetxea I (2012) Effect of cutting parameters in the surface residual stresses generated by turning in AISI 4340 steel. Int J Mach Tools Manuf 61:48–57
Childs T, Maekawa K, Obikawa T, Yamane Y (2000) Metal machining. Theory and applications. Wiley, New York
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Madariaga, A., Esnaola, J.A., Fernandez, E. et al. Analysis of residual stress and work-hardened profiles on Inconel 718 when face turning with large-nose radius tools. Int J Adv Manuf Technol 71, 1587–1598 (2014). https://doi.org/10.1007/s00170-013-5585-6
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-013-5585-6