Abstract
In machining of Inconel 718, various difficulties such as increased tool wear and poor machined surface quality are frequently encountered due to its high temperature strength and poor thermal properties. This work considers the effect of number of passes and the machining environment on the machined surface quality in ball end milling of Inconel 718, which hitherto has not been adequately understood. To this effect, extensive experimentation has been carried out to analyze machined surface quality and integrity in terms of surface roughness, surface damage, and microhardness variation in the machined surfaces. The machined surfaces show formation of distinct bands as a function of instantaneous machining parameters along the periphery of cutting tool edge. A distinct variation is also observed in the measured values of surface roughness and microhardness in these regions. The minimum surface roughness is obtained in the stable cutting zone and it increases toward the periphery of the cutter on band #2 and band #3. Microhardness of depth beneath the machined surface shows that the machining affected zone varies from 60 to 100 µm in ball end milling under various machining conditions.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
R. Arunachalam, M.A. Mannan et al., Machinability of Nickel-Based High Temperature Alloys, J. Mach. Sci. Technol., 2000, 4(1), p 127–168
E.O. Ezugwu, J. Bonney, and Y. Yamane, An Overview of the Machinability of Aero Engine Alloy, J. Mater. Proc. Technol., 2003, 135(1), p p233–p253
R.S. Pawade, S.S. Joshi, P.K. Brahmankar, and M. Rahman, An Investigation of Cutting Forces and Surface Damage in High-Speed Turning of Inconel 718, J. Mater. Proc. Technol., 2007, 192(19), p p139–p146
Zhaoliang. Jiang, Yumei. Lui et al., A Novel Prediction Model for Thin Plate Deflection Considering Milling of Residual Stresses, J. Adv. Manuf. Technol., 2014, 74, p 37–45
C. Lee, S. Kim, K. Choi, and D. Lee, Evaluation of Cutter Orientations in High Speed Ball End Milling of Cantilever-Shaped Thin Plate, J. Mater. Proc. Technol., 2003, 140(1–3), p 231–236
R. Zhu, S.G. Kapoor, and R.E. DeVor, Mechanistic Modeling of the Ball End Milling Process for Multi-axis Machining of Free Form Surfaces, J. Manuf. Sci. Eng., 2001, 123(3), p 369–379
D.K. Aspinwall and R.C. Sharman, High Speed Ball Nose end Milling of Inconel 718, CIRP Ann. Manuf. Technol., 2001, 49(1), p 41–46
Harshad.A. Sonawane and Suhas.S. Joshi, Analytical Modeling of Chip Geometry and Cutting Forces in Helical Ball End Milling of Super Alloy Inconel 718, CIRP Manuf. Sci. Technol., 2010, 3(3), p 204–217
K.D. Bouzakis, P. Aichouh, and K. Efstathiou, Determination of the Chip Geometry, Cutting Force and Roughness in Free Form Surfaces Finishing Milling with Ball End Tools, J. Mach. Tools Manuf., 2003, 43(5), p 499–514
A. Antoniadis, C. Savakis, N. Bilalis, and A. Balouktsis, Prediction of Surface Topomorphy and Roughness in Ball End Milling, J. Adv. Manuf. Technol., 2003, 21, p 965–971
Harshad.A. Sonawane and Suhas.S. Joshi, Analysis of Machined Surface Quality in a Single-Pass of Ball-End Milling on Inconel 718, J Manuf. Proc., 2012, 14(3), p 257–268
Y. Mizugaki, K. Kikkawa, H. Terai, and M. Hao, Theoretical Estimation of Machined Surface Profile Based on Cutting Edge Movement and Tool Orientation in Ball Nosed End Milling, CIRP Ann., 2003, 529(1), p 49–52
M. Arizmendi, J. Fernandez, A. Lamikiz, A. Gil, and J.A. Sanchez, Model Development for the Reduction of Surface Topography Generated by Ball-End Mills Taking into Account the Tool Parallel Axis Offset Experimental Validation, CIRP Ann. Manuf. Technol., 2008, 57(1), p 101–104
A. Shokrani, V. Dhokia, S.T. Newman, and R. Imani-Asrai, An Initial Study of the Effect of Using Liquid Nitrogen Coolant on the Surface Roughness of Inconel 718 in CNC milling, CIRP Proc., 2012, 3, p 121–125
M.S. Kasim, C.H. Che Haron, J.A. Ghani, M.A. Sulaiman, and M.Z.A. Yazid, Wear Mechanism and Notch Wear Location Prediction Model in Ball Nose End Milling of Inconel 718, Wear, 2013, 302(1–2), p 1171–1179
I. Ucun, K. Aslantas, and F. Bedir, An Experimental Investigation of the Effect of Coating Material on Tool Wear in Micro Milling of Inconel 718, Wear, 2013, 300(1–2), p 8–19
G.K. Dosbaeva, S.C. Veldhuis, A. Elfizy, G. Fox-Rabinovich, and T. Wagg, Microscopic Observations on the Origin of Defects During Machining of Direct Aged Inconel 718, J. Mater. Eng. Perform., 2010, 19(8), p 1193–1198
Bulent. Kaya, Cuneyt. Oysu, and Huseyin.M. Ertunc, Force-Torque Based On-Line Tool Wear Estimation System for CNC Milling of Inconel 718 Using Neural Networks, Adv. Eng. Soft, 2011, 42(1), p p76–p84
Kennametal Master Tooling Catalog, Sustainable Solution for Aerospace Manufacturing and Advance Material for a New Generation, 2012
M.S. Phadke, Quality Engineering Using Robust Design, Prentice Hall, Englewood Cliffs, 1989
B. Griffiths, Manufacturing Surface Technology, 1st ed., Elsevier, Amsterdam, 2001
S. Zhang, T.C. Ding, and J.F. Li, Microstructural Alteration and Microhardness at Near Surface of AISI, H13 Steel by Hard Milling, J. Mach. Sci. Technol., 2012, 16(3), p 473–486
Acknowledgments
Authors gratefully acknowledge the help provided by Sunil Sanap during the experimental work. Authors are grateful toward the guidance and help provided by Harshad Sonawane during testing of work specimen. Thanks are due to MHRD Govt. of India, TEQIP-I for providing the grant for CNC milling machine for the experimental work.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Bhopale, N.N., Joshi, S.S. & Pawade, R.S. Experimental Investigation into the Effect of Ball End Milling Parameters on Surface Integrity of Inconel 718. J. of Materi Eng and Perform 24, 986–998 (2015). https://doi.org/10.1007/s11665-014-1323-y
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-014-1323-y