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The effect of chip formation on the cutting force and tool wear in high-speed milling Inconel 718

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Abstract

Coated carbide tools are widely used in the processing of nickel-based superalloys due to their excellent wear resistance, high strength, and good hardness at high temperatures. In this paper, the high-speed milling experiments and finite element simulation of Inconel 718 are carried out by using PVD TiAlN-coated carbide tools. Simulations of tool temperature, cutting force, and chip morphology were performed to analyze the effect of cutting speed on the degree of sawtooth chip formation and the effect of sawtooth chip formation on the cutting force and tool wear. The results show that the cutting temperature mainly focuses on the rake face, and with the cutting speed increasing from 60 to 120 m/min, the maximum temperature of the rake face increases from 580 to 660 ℃. The maximum temperature region (MTR) on the rake face gradually approaches the tool nose with a decrease in the cutting speed. The generation of sawtooth chips leads to fluctuations in the cutting force component. As the cutting speed increases, the degree of chip sawing increases. The effect of the sawtooth chip on the fluctuation of the cutting force will also increase, thus increasing the degree of tool wear.

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Funding

This work is supported by the National Natural Science Foundation of China (Grant Nos. 51905286, 52075276) and the Science, education, and Industry Integration Project of Qilu University of Technology (Grant No. 2022PY006).

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan, 250353, China

    Guoqing Zhang, Jingjie Zhang, Guanghui Fan, Chonghai Xu & Jin Du

  2. Key Laboratory of Equipments Manufacturing and Intelligent Measurement and Control, China National Light Industry, Qilu University of Technology (Shandong Academy of Sciences), Jinan, 250353, China

    Guoqing Zhang, Jingjie Zhang, Guanghui Fan, Chonghai Xu & Jin Du

  3. School of Materials Science and Engineering, Shandong University, Jinan, 250061, China

    Jingjie Zhang

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Contributions

Guoqing Zhang: writing-review and editing, software, data curation, and writing-original draft. Jingjie Zhang: writing-review and editing, supervision, project administration, funding acquisition. Guanghui Fan: formal analysis, writing-review and editing. Chonghai Xu: supervision, methodology and conceptualization. Jin Du: supervision, methodology, and conceptualization.

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Correspondence to Jingjie Zhang.

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Zhang, G., Zhang, J., Fan, G. et al. The effect of chip formation on the cutting force and tool wear in high-speed milling Inconel 718. Int J Adv Manuf Technol 127, 335–348 (2023). https://doi.org/10.1007/s00170-023-11551-6

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