Improvement of cutting performance of carbide cutting tools in milling of the Inconel 718 superalloy using multilayer nanocomposite hard coating and cryogenic heat treatment ORIGINAL ARTICLE First Online: 03 April 2018 Received: 19 December 2017 Accepted: 16 March 2018 Abstract
In this study, milling of the Inconel 718 superalloy was performed in dry conditions with the aim of reducing the adverse effects of the coolant on the environment. As is known, cutting tools quickly complete their life due to the high-temperature on the cutting zone in the dry condition milling process of hard materials. The nanocomposite TiAlSiN/TiSiN/TiAlN thin film was deposited on the cutting tools and then subjected to cryogenic heat treatment to increase the tool life of the used cutting tools. As a result, the life of the cutting tools has been increased by the thin film coating and cryogenic heat treatment applied to the cutting tools. After cryogenic treatment at a cutting speed of 30 m/min, the tool life of uncoated, TiN-, nanocomposite TiAlSiN/TiSiN/TiAlN-, and TiAlN-coated carbide cutting tools increases by 54, 110, 29, and 30%. The applied cryogenic heat treatment resulted in an 18% increase in the hard
η phase of the structure of the carbide cutting tools. In addition, cryogenic heat treatment improved the adhesion of hard coatings to the substrate. The EDS analysis applied to the worn tools revealed that the mechanisms causing wear of the cutting tools were abrasion and adhesion. Keywords Inconel 718 Carbide cutting tool Hardmilling Cryogenic heat treatment Nanocomposite hard coatings Notes Acknowledgements
This work was supported by the Unit of Scientific Research Projects of Suleyman Demirel University, Turkey (project 3563-D2-13).
Thakur A, Gangopadhyay S (2016) State-of-the-art in surface integrity in machining of nickel-based super alloys. Int J Mach Tools Manuf 100:25–54.
https://doi.org/10.1016/j.ijmachtools.2015.10.001 CrossRef Google Scholar
Lu X, Jia Z, Wang H, Si L, Liu Y, Wu W (2016) Tool wear appearance and failure mechanism of coated carbide tools in micro-milling of Inconel 718 super alloy. Ind Lubr Tribol 68:267–277.
https://doi.org/10.1108/ILT-07-2015-0114 CrossRef Google Scholar
Kyncl J, Molotovnik A (2015) The research of the surface profile after profiling of superalloys. Energy Procedia 100:853–860.
https://doi.org/10.1016/j.proeng.2015.01.441 CrossRef Google Scholar
Liao Y-S, Liao C-H, Lin H-M (2017) Study of oil-water ratio and flow rate of MQL fluid in high speed milling of Inconel 718. Int J Precis Eng Manuf 18:257–262.
https://doi.org/10.1007/s12541-017-0033-4 CrossRef Google Scholar
de Paula Oliveira G, Cindra Fonseca M, Araujo AC (2017) Analysis of residual stress and cutting force in end milling of Inconel 718 using conventional flood cooling and minimum quantity lubrication. Int J Adv Manuf Technol 92:1–8.
https://doi.org/10.1007/s00170-017-0381-3 CrossRef Google Scholar
Uçak N, Çiçek A (2018) The effects of cutting conditions on cutting temperature and hole quality in drilling of Inconel 718 using solid carbide drills. J Manuf Process 31:662–673.
https://doi.org/10.1016/J.JMAPRO.2018.01.003 CrossRef Google Scholar
Zhang B, Njora MJ, Sato Y (2018) High-speed turning of Inconel 718 by using TiAlN- and (Al, Ti) N-coated carbide tools. Int J Adv Manuf Technol.
Kuppuswamy R, Zunega J, Naidoo S (2017) Flank wear assessment on discrete machining process behavior for Inconel 718. Int J Adv Manuf Technol 93:2097–2109.
https://doi.org/10.1007/s00170-017-0623-4 CrossRef Google Scholar
Zhu D, Zhang X, Ding H (2013) Tool wear characteristics in machining of nickel-based superalloys. Int J Mach Tools Manuf 64:60–77.
https://doi.org/10.1016/j.ijmachtools.2012.08.001 CrossRef Google Scholar
Ucun I, Aslantas K, Bedir F (2015) The performance of DLC-coated and uncoated ultra-fine carbide tools in micromilling of Inconel 718. Precis Eng 41:135–144.
https://doi.org/10.1016/j.precisioneng.2015.01.002 CrossRef Google Scholar
Park K-H, Yang G-D, Lee DY (2015) Tool wear analysis on coated and uncoated carbide tools in inconel machining. Int J Precis Eng Manuf 16:1639–1645.
https://doi.org/10.1007/s12541-015-0215-x CrossRef Google Scholar
Dong X (2013) Handbook of manufacturing engineering and technology.
El-Hofy H (2014) Metal cutting operations and terminology
Zetek M, Česáková I, Švarc V (2014) Increasing cutting tool life when machining inconel 718. Procedia Eng 69:1115–1124.
https://doi.org/10.1016/j.proeng.2014.03.099 CrossRef Google Scholar
Wakabayashi T, Maeda Y, Iwatsuka K, Yazawa T (2014) Tool wear characteristics for near-dry cutting of Inconel 718. Key Eng Mater 625:282–287.
https://doi.org/10.4028/www.scientific.net/KEM.625.282 CrossRef Google Scholar
Vogtel P, Klocke F, Lung D (2014) High performance machining of profiled slots in nickel-based-superalloys. Procedia CIRP 14:54–59.
https://doi.org/10.1016/j.procir.2014.03.061 CrossRef Google Scholar
Thakur A, Gangopadhyay S, Maity KP (2014) Effect of cutting speed and tool coating on machined surface integrity of ni-based super alloy. Procedia CIRP 14:541–545.
https://doi.org/10.1016/j.procir.2014.03.045 CrossRef Google Scholar
Razak NH, Chen ZW, Pasang T (2016) Progression of tool deterioration and related cutting force during milling of 718Plus superalloy using cemented tungsten carbide tools. Int J Adv Manuf Technol 86:3203–3216.
https://doi.org/10.1007/s00170-016-8438-2 CrossRef Google Scholar
Li W, Guo YB, Barkey ME, Jordon JB (2014) Effect tool wear during end milling on the surface integrity and fatigue life of Inconel 718. Procedia CIRP 14:546–551.
https://doi.org/10.1016/j.procir.2014.03.056 CrossRef Google Scholar
Kasim MS, Che Haron CH, Ghani JA, Hadi MA, Izamshah R, Anand TJS, Mohamed SB (2016) Cost evaluation on performance of a PVD coated cutting tool during end-milling of Inconel 718 under MQL conditions. Trans Inst Met Finish 94:175–181.
https://doi.org/10.1080/00202967.2016.1179472 CrossRef Google Scholar
Krolczyk GM, Nieslony P, Maruda RW, Wojciechowski S (2017) Dry cutting effect in turning of a duplex stainless steel as a key factor in clean production. J Clean Prod 142:3343–3354.
https://doi.org/10.1016/j.jclepro.2016.10.136 CrossRef Google Scholar
Wojciechowski S, Maruda WR, Krolczyk GM, Niesłony P (2018) Application of signal to noise ratio and grey relational analysis to minimize forces and vibrations during precise ball end milling. Precis Eng 51:582–596.
https://doi.org/10.1016/J.PRECISIONENG.2017.10.014 CrossRef Google Scholar
Twardowski P, Legutko S, Krolczyk GM, Hloch S (2015) Investigation of wear and tool life of coated carbide and cubic boron nitride cutting tools in high speed milling. Advances in. Mech Eng 7:1687814015590216.
https://doi.org/10.1177/1687814015590216 Google Scholar
Kursuncu B, Yaras A (2017) Assessment of the effect of borax and boric acid additives in cutting fluids on milling of AISI O2 using MQL system. Int J Adv Manuf Technol 1–9
Deshpande YV, Andhare AB, Padole PM (2018) Experimental results on the performance of cryogenic treatment of tool and minimum quantity lubrication for machinability improvement in the turning of Inconel 718. J Braz Soc Mech Sci Eng 40:6.
https://doi.org/10.1007/s40430-017-0920-8 CrossRef Google Scholar
Inspektor A, Salvador PA (2014) Architecture of PVD coatings for metal cutting applications: a review. Surf Coat Technol 257:138–153.
https://doi.org/10.1016/j.surfcoat.2014.08.068 CrossRef Google Scholar
Hao Z, Fan Y, Lin J, Yu Z (2015) Wear characteristics and wear control method of PVD-coated carbide tool in turning Inconel 718. Int J Adv Manuf Technol 78:1329–1336.
https://doi.org/10.1007/s00170-014-6752-0 CrossRef Google Scholar
Kursuncu B, Caliskan H, Guven SY, Panjan P (2017) Wear behavior of multilayer nanocomposite TiAlSiN/TiSiN/TiAlN coated carbide cutting tool during face milling of inconel 718 superalloy. J Nano Res 47:11–16.
https://doi.org/10.4028/www.scientific.net/JNanoR.47.11 CrossRef Google Scholar
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.
https://doi.org/10.1016/j.triboint.2009.12.053 CrossRef Google Scholar
Devillez A, Le Coz G, Dominiak S, Dudzinski D (2011) Dry machining of Inconel 718, workpiece surface integrity. J Mater Process Technol 211:1590–1598.
https://doi.org/10.1016/j.jmatprotec.2011.04.011 CrossRef Google Scholar
Kalinga Simant Bal B, Maity K (2012) Performance Appraisal of Cryo-Treated Tool By Performance Appraisal of Cryo-Treated Tool By Turning Operation
Akincioğlu S, Gökkaya H, İlyas U (2015) A review of cryogenic treatment on cutting tools. Int J Adv Manuf Technol 78:1609–1627.
https://doi.org/10.1007/s00170-014-6755-x CrossRef Google Scholar
Gu K, Wang J, Zhou Y (2014) Effect of cryogenic treatment on wear resistance of Ti-6Al-4V alloy for biomedical applications. J Mech Behav Biomed Mater 30:131–139.
https://doi.org/10.1016/j.jmbbm.2013.11.003 CrossRef Google Scholar
Vadivel K, Rudramoorthy R (2009) Performance analysis of cryogenically treated coated carbide inserts. Int J Adv Manuf Technol 42:222–232.
https://doi.org/10.1007/s00170-008-1597-z CrossRef Google Scholar
Firouzdor V, Nejati E, Khomamizadeh F (2008) Effect of deep cryogenic treatment on wear resistance and tool life of M2 HSS drill. J Mater Process Technol 206:467–472.
https://doi.org/10.1016/j.jmatprotec.2007.12.072 CrossRef Google Scholar
Senthilkumar D, Rajendran I (2011) Influence of shallow and deep cryogenic treatment on tribological behavior of En 19 steel. J Iron Steel Res Int 18:53–59.
https://doi.org/10.1016/S1006-706X(12)60034-X CrossRef Google Scholar
Podgornik B, Leskovsek V, Vizintin J (2009) Influence of deep-cryogenic treatment on tribological properties of P/M high-speed steel. Mater Manuf Process 24:734–738.
https://doi.org/10.1080/10426910902809339 CrossRef Google Scholar
Chopra SA, Sargade VG (2015) Metallurgy behind the cryogenic treatment of cutting tools: an overview. Mater Today Proc 2:1814–1824.
https://doi.org/10.1016/j.matpr.2015.07.119 CrossRef Google Scholar
Patil HB, Chavan PB, Kazi SH (2013) Effects of cryogenic on tool steels—a review. Int J Mech Prod Eng 31–36
Gill SS, Singh H, Singh R, Singh J (2011) Flank wear and machining performance of cryogenically treated tungsten carbide inserts. Mater Manuf Process 26:1430–1441.
https://doi.org/10.1080/10426914.2011.557128 MathSciNet CrossRef Google Scholar
Bensely A, Prabhakaran A, Mohan Lal D, Nagarajan G (2005) Enhancing the wear resistance of case carburized steel (En 353) by cryogenic treatment. Cryogenics 45:747–754.
https://doi.org/10.1016/j.cryogenics.2005.10.004 CrossRef Google Scholar
Mohan Lal D, Renganarayanan S, Kalanidhi A (2001) Cryogenic treatment to augment wear resistance of tool and die steels. Cryogenics 41:149–155.
https://doi.org/10.1016/S0011-2275(01)00065-0 CrossRef Google Scholar
Gogte CL, Iyer KM, Paretkar RK, Peshwe DR (2009) Deep subzero processing of metals and alloys: evolution of microstructure of AISI T42 tool steel. Mater Manuf Process 24:718–722.
https://doi.org/10.1080/10426910902806210 CrossRef Google Scholar
Yong AYL, Seah KHW, Rahman M (2006) Performance evaluation of cryogenically treated tungsten carbide tools in turning. Int J Mach Tools Manuf 46:2051–2056.
https://doi.org/10.1016/j.ijmachtools.2006.01.002 CrossRef Google Scholar
Gill SS, Singh J, Singh H, Singh R (2012) Metallurgical and mechanical characteristics of cryogenically treated tungsten carbide (WC-Co). Int J Adv Manuf Technol 58:119–131.
https://doi.org/10.1007/s00170-011-3369-4 CrossRef Google Scholar
SreeramaReddy TV, Sornakumar T, VenkataramaReddy M, Venkatram R (2009) Machinability of C45 steel with deep cryogenic treated tungsten carbide cutting tool inserts. Int J Refract Met Hard Mater 27:181–185.
https://doi.org/10.1016/j.ijrmhm.2008.04.007 CrossRef Google Scholar
Özbek NA, Çiçek A, Gülesin M, Özbek O (2016) Effect of cutting conditions on wear performance of cryogenically treated tungsten carbide inserts in dry turning of stainless steel. Tribol Int 94:223–233.
https://doi.org/10.1016/j.triboint.2015.08.024 CrossRef Google Scholar
Çalişkan H, Küçükköse M (2015) The effect of aCN/TiAlN coating on tool wear, cutting force, surface finish and chip morphology in face milling of Ti6Al4V superalloy. Int J Refract Met Hard Mater 50:304–312.
https://doi.org/10.1016/j.ijrmhm.2015.02.012 CrossRef Google Scholar
Chetan, Ghosh S, Rao PV (2017) Performance evaluation of deep cryogenic processed carbide inserts during dry turning of Nimonic 90 aerospace grade alloy. Tribol Int 115:397–408.
https://doi.org/10.1016/J.TRIBOINT.2017.06.013 CrossRef Google Scholar
Thamizhmanii S, Nagib M, Sulaiman H (2011) Performance of deep cryogenically treated and non-treated PVD inserts in milling. J Achiev Mater Manuf Eng 49:460–466
Yong AYL, Seah KHW, Rahman M (2007) Performance of cryogenically treated tungsten carbide tools in milling operations. Int J Adv Manuf Technol 32:638–643.
https://doi.org/10.1007/s00170-005-0379-0 CrossRef Google Scholar
Caliskan H, Celil CC, Panjan P (2016) Effect of multilayer nanocomposite TiAlSiN/TiSiN/TiAlN coating on wear behavior of carbide tools in the milling of hardened AISI D2 steel. J Nano Res 38:9–17.
https://doi.org/10.4028/www.scientific.net/JNanoR.38.9 CrossRef Google Scholar Copyright information
© Springer-Verlag London Ltd., part of Springer Nature 2018