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Machined surface integrity of inconel 718 in high-speed dry milling using SiAlON ceramic tools

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Abstract

The surface integrity of complex engineering components has a major effect on their mechanical properties. Recently, modern ceramic tools have demonstrated themselves as potential candidates for high-speed machining of heat-resistant superalloys, delivering a substantial increase in productivity. The results of previous studies showed that after surpassing a cutting speed of 800 m/min, the cutting forces experienced a sharp decrease accompanied by a reduction in tool wear. However, in such applications, extreme temperature and mechanical loads are generated at the cutting zone, implying a possible negative influence on the machined surface integrity. In this study, numerous characterizations have been performed to evaluate the different aspects of inconel 718–machined surface integrity after face milling with SiAlON cutting tools at the range of 900 m/min. Since the cutting conditions are remarkably far from those experienced during conventional cutting, the results are also compared to those obtained during conventional milling of inconel with a commonly used commercial coated carbide tool. Results showed that the milling process induces tensile residual stresses as high as 2 GPa on the machined surface while generating an unwanted white layer with a thickness of around 1 μ and a relatively rough surface with Ra = 4.5 μm as compared to surfaces machined with conventional carbide tools at Ra = 2.2 μm. No major work-hardening effect was observed. Nevertheless, imperfections were observed to be contained within a thin sub-layer of the workpiece, suggesting that the ceramic tools can be used for roughing processes provided further finishing operations performed to remove the damaged layer.

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Funding

This research was supported by the Natural Sciences and Engineering Research Council of Canada (NSERC) under the CANRIMT Strategic Research Network Grant NETGP 479639-15.

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Authors and Affiliations

  1. Department of Mechanical Engineering, McMaster Manufacturing Research Institute (MMRI), McMaster University, 1280 Main Street West, Hamilton, Ontario, L8S 4L7, Canada

    Farhad Molaiekiya, Ali Aliakbari Khoei, Maryam Aramesh & Stephen C. Veldhuis

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  1. Farhad Molaiekiya
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  2. Ali Aliakbari Khoei
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  3. Maryam Aramesh
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  4. Stephen C. Veldhuis
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Contributions

Farhad Molaiekiya conceptualized and performed the experiments, analyzed and interpreted the results, and wrote and prepared the manuscript; Ali Khoei assisted with XRD experiments and assisted with reviewing and editing; Maryam Aramesh assisted with writing, reviewing, and editing; Stephen C. Veldhuis supervised and administered the project.

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Correspondence to Farhad Molaiekiya.

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Molaiekiya, F., Aliakbari Khoei, A., Aramesh, M. et al. Machined surface integrity of inconel 718 in high-speed dry milling using SiAlON ceramic tools. Int J Adv Manuf Technol 112, 1941–1950 (2021). https://doi.org/10.1007/s00170-020-06471-8

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  • DOI: https://doi.org/10.1007/s00170-020-06471-8

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