Characterization of tool wear when machining alloy 718 with high-pressure cooling using conventional and surface-modified WC–Co tools

Abstract

Characterization of tool wear when machining Alloy 718 with high pressure cooling using conventional and surface-modified WC-Co tools Coolant supplied by high pressure into the cutting zone has shown the lower thermal loads on the tool when machining difficult-to-cut materials as the Alloy 718. In this study, we investigate how the combination of high-pressure cooling and tool-surface modifications can lead to further improvements regarding tool life. The general approach is to enhance the coolant-tool interaction by increasing the contact area. Therefore, we machined cooling features into flank and rake faces of commercially available cemented tungsten carbide inserts. In this way, the surface area was increased by ~ 12 %. After the cutting tests, the tools were analyzed by scanning electron microscopy combined with energy-dispersive X-ray spectroscopy. Compared with conventional tools, the tool modifications reduced the flank wear by 45 % for the investigated cutting parameters. Furthermore, we were able to significantly increase the cutting speed and feed rate without failure of the tool. The investigated surface modifications have great potential to enhance the productivity of metal cutting processes.

Pareto Analysis of Machining Factors Significance When Turning of Nickel-Based Superalloy Inconel 718

“…High pressure promotes better liquid penetration into the tool-workpiece and tool-chip interface zones (Figure 6) [40]. It was found that increasing the contact area by 12% reduces flank wear by 45% for a carbide tool [44]. H. Khochtali et al [10] compared the conventional cooling method and the HPC method for a coated carbide tool.…”

“…The oil mixes with the air, forming an aerosol, and is fed close to the cutting edge. In an MQL It was found that increasing the contact area by 12% reduces flank wear by 45% for a carbide tool [44]. H. Khochtali et al [10] compared the conventional cooling method and the HPC method for a coated carbide tool.…”

A review on cutting tool technology in machining of Ni-based superalloys

“…Ezugwu and Bonney [73] experimented with the HPC machining of Inconel 718 by using a coated carbide, the result of which showed that the tool life was prolonged by increasing the coolant pressure and an ideal "C" shape chip was obtained under 203 bar. A HPC condition provided a textured surface carbide tool with a 45% reduction of flank wear compared with a normal tool [74]. A laser-assisted HSM under dry condition was tested by using coated carbide tools (single-layer TiAlN PVD and triple-layer (TiCN/Al 2 O 3 /TiN) CVD), considering a purely dry condition does not fit in machining of superalloys [75].…”

“…For example, textured cutting tools which can be machined by laser [107,108] or grinding [109,110] have shown a great potential in the process of machining, with improved cutting performance in terms of machining quality and tool life. The textures on the tool surface provided a significant improvement against tool wear in the machining of superalloys [74,111]. From the reported articles, textures on 0 2 4 6 8 10 12 1957 1968 1988 1989 1992 1994 1997 1998 1999 2000 2001 2003 2004 2006 2007 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 The data collecƟon before 01 April 2020 Differences between big data analytics and conventional methods the tool surface could change the status of wear and provide macro-pools for coolants.…”