Effects of high-pressure cooling on the wear patterns on turning inserts used on alloy IN718

Suárez, Alejandro Rosete; Lacalle, Luís Norberto López de; Polvorosa, R.; Veiga, Fernando; Wretland, Anders

doi:10.1080/10426914.2016.1244838

Cited by 81 publications

(38 citation statements)

References 18 publications

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“…This constitutive law defines the effective flow stress following the expression given in Equation (2). The first term of Equation (2) defines the strain hardening due to plastic deformation (ε p ) depending on the reference yield stress A and the material constants B and n. The second term accounts for strain rate sensitivity ( .ε p ) through the material parameter C and the reference strain rate .ε 0 .…”

Section: Modelling Of the Thermo-viscoplastic Behaviormentioning

confidence: 99%

“…Ni-based superalloys (being about 50% of the weight in an aerospace engine) offer high strength at high temperatures, fatigue strength, thermal stability, and resistance to corrosion under aggressive environmental conditions [1], being widely used in aerospace engines and gas turbines. However, due to their good mechanical properties, nickel-based superalloys are difficult to machine and expensive (see, for instance, [2,3]). …”

Section: Introductionmentioning

confidence: 99%

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Thermo-Viscoplastic Behavior of Ni-Based Superalloy Haynes 282 and Its Application to Machining Simulation

Rodríguez-Millán

Díaz-Álvarez

Bernier

et al. 2017

Metals

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Abstract:Ni-based superalloys are extensively used in high-responsibility applications in components of aerospace engines and gas turbines with high temperature service lives. The wrought, γ'-strengthened superalloy Haynes 282 has been recently developed for applications similar to other common superalloys, such as Waspaloy or Inconel 718, with improved creep behavior, thermal stability, and fabrication ability. Despite the potential of Haynes 282, there are still important gaps in the knowledge of the mechanical behavior of this alloy. In fact, it was not possible to find information concerning the mechanical behavior of the alloy under impulsive loading. This paper focuses on the mechanical characterization of the Haynes 282 at strain rates ranging from 0.1 to 2800 s −1 and high temperatures ranging from 293 to 523 K using Hopkinson bar compression tests. The experimental results from the thermo-mechanical characterization allowed for calibration of the Johnson-Cook model widely used in modeling metallic alloy's responses under dynamic loading. Moreover, the behavior of Haynes 282 was compared to that reported for Inconel 718, and the results were used to successfully model the orthogonal cutting of Haynes 282, being a typical case of dynamic loading requiring previous characterization of the alloy.

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Section: Modelling Of the Thermo-viscoplastic Behaviormentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Thermo-Viscoplastic Behavior of Ni-Based Superalloy Haynes 282 and Its Application to Machining Simulation

Rodríguez-Millán

Díaz-Álvarez

Bernier

et al. 2017

Metals

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show abstract

“…The chemical composition, mechanical, and physical properties of tested materials are shown in Table 1. Due to aggressive conditions at which IBRs are exposed, such as high temperatures and aggressive chemical environments, they are manufactured using nickel-base superalloys [24]. In particular Inconel 718 was chosen.…”

Section: Experimental Setup and Tests Performancementioning

confidence: 99%

Super Abrasive Machining of Integral Rotary Components Using Grinding Flank Tools

González

Calleja

Pereira

et al. 2018

Metals

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Manufacturing techniques that are applied to turbomachinery components represent a challenge in the aeronautic sector. These components require high resistant super-alloys in order to satisfy the extreme working conditions they have to support during their useful life. Besides, in the particular case of Integrally Bladed Rotors (IBR), usually present complex geometries that need to be roughed and finished by milling and grinding processes, respectively. In order to improve their manufacturing processes, Super Abrasive Machining (SAM) is presented as a solution because it combines the advantages of the use of grinding tools with milling feed rates. However, this innovative technique usually needed high tool rotary speed and pure cutting oils cooling. These issues implied that SAM technique was not feasible in conventional machining centers. In this work, these matters were tackled and the possibility of using SAM in these five-axis centers with emulsion coolants was achieved. To verify this approach, Inconel 718 single blades with non-ruled surfaces were manufactured with Flank-SAM technique and conventional milling process, analyzing cutting forces, surface roughness, and dimension accuracy in both cases. The results show that SAM implies a suitable, controllable, and predictable process to improve the manufacture of aeronautical critical components, such as IBR.

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“…The use of new advanced materials has played a major role on this improvement; hence, up to 50% of the increase obtained in turbines efficiency is attributed to super alloys (nickel base) and titanium alloys, both kinds included in the group S (orange) in the ISO (513:2012) materials classification. The development of nickel-based superalloys led into an increase in the turbine entrance temperature up to 350 ∘ C over the last decades, and thus during the next years an increase of 200 ∘ C in the entrance temperature is estimated, based on Clean Sky European initiative [1,2]. In manufacturing of turbines, turning is the most important operation for cases and disks for all kind of engine segments.…”

Section: Introductionmentioning

confidence: 99%

Wear-dependent specific coefficients in a mechanistic model for turning of nickel-based superalloy with ceramic tools

Lacalle

Urbikaín

Fernández-Valdivielso

et al. 2017

Open Engineering

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Difficult to cut materials such as nickel and titanium alloys are used in the aeronautical industry, the former alloys due to its heat-resistant behavior and the latter for the low weight -high strength ratio. Ceramic tools made out alumina with reinforce SiC whiskers are a choice in turning for roughing and semifinishing workpiece stages. Wear rate is high in the machining of these alloys, and consequently cutting forces tends to increase along one operation. This paper establishes the cutting force relation between work-piece and tool in the turning of such difficult-to-cut alloys by means of a mechanistic cutting force model that considers the tool wear effect. The cutting force model demonstrates the force sensitivity to the cutting engagement parameters (ap, f) when using ceramic inserts and wear is considered. Wear is introduced through a cutting time factor, being useful in real conditions taking into account that wear quickly appears in alloys machining. A good accuracy in the cutting force model coefficients is the key issue for an accurate prediction of turning forces, which could be used as criteria for tool replacement or as input for chatter or other models.

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Effects of high-pressure cooling on the wear patterns on turning inserts used on alloy IN718

Cited by 81 publications

References 18 publications

Thermo-Viscoplastic Behavior of Ni-Based Superalloy Haynes 282 and Its Application to Machining Simulation

Thermo-Viscoplastic Behavior of Ni-Based Superalloy Haynes 282 and Its Application to Machining Simulation

Super Abrasive Machining of Integral Rotary Components Using Grinding Flank Tools

Wear-dependent specific coefficients in a mechanistic model for turning of nickel-based superalloy with ceramic tools

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