Skip to main content

Tool life and tool wear in taper turning of a nickel-based superalloy

The International Journal of Advanced Manufacturing Technology volume 87, pages 2023–2032 (2016)Cite this article

Abstract

Due to their high ductility and strain hardening coefficient, high mechanical strength and hardness even in high temperatures, chemical affinity with almost every tool material, and low thermal conductivity, nickel-based superalloys are known to present very low machinability. Some researchers point out that taper turning may prolong tool life as ramping may distribute tool wear along tool edge, avoiding the presence of notch wear in the end of the depth of cut, which usually occurs in the tools used in turning of these alloys. In this work, tool life, tool wear, and resulting surface roughness of Inconel 625 were evaluated for taper turning in comparison with straight turning. In taper turning, double feed was tested to compensate metal removal rate reduction (since in this operation, the feed length is doubled), and in order to avoid roughness increase caused by the higher feed, a wiper tool was used. Results show that taper turning was not successful in terms of tool life, although the furrowing mechanism of the tool coating caused by the hard burr formed, that leads to notch wear, was avoided. This mechanism was replaced by strong adhesion that promoted rapid and wide flank wear. Feed increase has also produced microchipping due to the extra load on the tool edge. Although wiper tool had provided better finishing when high feed was employed, conventional tool seems to be more suitable for tapering considering tool life.

This is a preview of subscription content, access via your institution.

Access options

Buy single article

Instant access to the full article PDF.

USD 39.95

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

References

  1. Antolovich BF (1996) Fatigue and fracture of nickel-base superalloys, in: ASM Handbook, pp. 854–868

  2. Trent EM, Wright PK (2000) Metal Cutting, forth.ed. Butterworth-Heinemann, Woburn

  3. Zhuang K, Zhu D, Zhang X, Ding H (2014) Notch wear prediction model in turning of Inconel 718 with ceramic tools considering the influence of work hardened layer. Wear 313:63–74

    Article  Google Scholar 

  4. Diniz AE, Marcondes FC, Coppini NL (2014) Tecnologia da usinagem dos materiais, 9th edn. Artliber, São Paulo

    Google Scholar 

  5. Ezugwu EO (2005) Key improvements in the machining of difficult-to-cut aerospace superalloys. Int J Mach Tools Manuf 45:1353–1367

    Article  Google Scholar 

  6. Stephenson DA, Skerlos SJ, King AS, Supekar SD (2014) Rough turning Inconel 750 with supercritical CO2-based minimum quantity lubrication. J Mater Process Technol 214:673–680

    Article  Google Scholar 

  7. Carou D, Rubio EM, Davim JP (2015) A note on the use of the minimum quantity lubrication (MQL) system in turning. Ind Lubr Tribol 67:256–261

    Article  Google Scholar 

  8. Kamata Y, Obikawa T (2007) High speed MQL finish-turning of Inconel 718 with different coated tools. J Mater Process Technol 192–193:281–286

    Article  Google Scholar 

  9. Thakur A, Gangopadhyay S, Maity KP (2014) Effect of cutting speed and CVD multilayer coating on machinability of Inconel 825. Surf Eng 30:516–523

    Article  Google Scholar 

  10. Bhatt A, Attia H, Vargas R, Thomson V (2010) Wear mechanisms of WC coated and uncoated tools in finish turning of Inconel 718. Tribol Int 43:1113–1121

    Article  Google Scholar 

  11. Settineri L, Faga MG, Lerga B (2008) Properties and performances of innovative coated tools for turning inconel. Int J Mach Tools Manuf 48:815–823

    Article  Google Scholar 

  12. 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 Annu Manuf Technol 57:77–80

    Article  Google Scholar 

  13. Ulutan D, Ozel T (2011) Machining induced surface integrity in titanium and nickel alloys: a review. Int J Mach Tools Manuf 51:250–280

    Article  Google Scholar 

  14. Fan YH, Hao ZP, Zheng ML, Sun FL, Yang SC (2013) Study of surface quality in machining nickel-based alloy Inconel 718. Int J Adv Manuf Technol 69:2659–2667

    Article  Google Scholar 

  15. Sharman ARC, Hughes JI, Ridgway K (2008) Surface integrity and tool life when turning Inconel 718 using ultra-high pressure and flood coolant systems. P I Mech Eng B-J Eng 222:653–664

    Google Scholar 

  16. Hao Z, Gao D, Fan Y, Han R (2011) New observations on tool wear mechanism in dry machining Inconel 718. Int J Mach Tools Manuf 51:973–979

    Article  Google Scholar 

  17. Cantero JL, Díaz-Álvarez J, Miguélez MH, Marín NC (2013) Analysis of tool wear patterns in finishing turning of Inconel 718. Wear 297:885–894

    Article  Google Scholar 

  18. Hao ZP, Fan YH, Lin JQ, Yu ZX (2015) Wear characteristics and wear control method of PVD-coated carbide tool in turning Inconel 718. Int J Adv Manuf Technol 78:1329–1336

    Article  Google Scholar 

  19. Zhu D, Zhang X, Ding H (2013) Tool wear characteristics in machining of nickel-based superalloys. Int J Mach Tools Manuf 64:60–77

    Article  Google Scholar 

  20. ASTM, B446, West Conshohocken, 2014

  21. Coromant S (2012) Torneamento geral, in: Ferramentas para torneamento, pp. A1-A529

  22. ASTM (2007) E407, West Conshohocken

  23. Klocke F (2011) Cutting, in: Manufacturing processes, 504 p

  24. ABNT (2002) NBR ISO 4287, Rio de Janeiro

  25. Coromant S (2005) Manual técnico de usinagem, São Paulo

  26. Biermann D, Heilmann M (2010) Burr minimization strategies in machining operations. In: Aurich JC, Dornfeld D (eds) Burrs - analysis, control and removal. Springer, Berlin, pp 13–20

    Chapter  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering (DEMec/UFSCar), Federal University of São Carlos, Rod. Washington Luís, km 235, PO Box 676, 13.565-905, São Carlos, São Paulo, Brazil

    A. Í. S. Antonialli

  2. Faculty of Mechanical Engineering, University of Campinas, Campinas, São Paulo, Brazil

    A. Magri & A. E. Diniz

Authors
  1. A. Í. S. Antonialli
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. Magri
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. E. Diniz
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to A. Í. S. Antonialli.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Antonialli, A.Í.S., Magri, A. & Diniz, A.E. Tool life and tool wear in taper turning of a nickel-based superalloy. Int J Adv Manuf Technol 87, 2023–2032 (2016). https://doi.org/10.1007/s00170-016-8568-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-8568-6

Keywords

  • Inconel
  • Tapering
  • Chip removal
  • Tool wear
  • Surface roughness