Experimental Study on Surface Integrity in End Milling of Hastelloy C-2000 Superalloy

Abstract

This paper presents an experimental study of surface integrity in end milling of Hastelloy C-2000. The experiment was carried out using two different cutting inserts under wet conditions -namely physical vapor deposition coated carbide with TiAlN and uncoated carbide. Design of experiment was implemented with a Box-Behnken design. The surface integrity of the workpiece was analyzed through scanning electron microscopy (SEM) and chemical element changes were inspected by an energy dispersive X-ray (EDX) test. The surface integrity of Hastelloy C-2000 was better when machining with coated carbide compared to uncoated carbide cutting inserts, mainly because the coating layer of coated carbide acted as a protecting layer to the cutting tool insert. Surface defects such as feed marks, surface tearing, plucking, cracking and adhered chips were found during the machining process. The chemical element changes happened due to the adhesion and diffusion mechanisms which were identified using SEM and EDX.

Cutting force and chip formation in end milling operation when machining nickelbased superalloy, Hastelloy C-2000

“…Nickel-based alloys (Ni-Co-Cr, Ni-Fe-Cr or Ni-Co-Fe) are very popular in the industry owing to their advantages over titanium-based alloys [1][2][3]. The main strengths of nickelbased alloys are heat resistance, retaining their high mechanical and chemical properties at high temperatures, and having high melting temperatures, high corrosion resistance, as well as resistance to thermal fatigue, thermal shock, creep, and erosion [4][5][6].…”

“…The main strengths of nickelbased alloys are heat resistance, retaining their high mechanical and chemical properties at high temperatures, and having high melting temperatures, high corrosion resistance, as well as resistance to thermal fatigue, thermal shock, creep, and erosion [4][5][6]. Nickelbased alloys have the ability to retain most of their strength, even after long exposure to extremely high temperatures and are the only material suitable for turbine sections of jet engines.…”

“…Nickelbased alloys have the ability to retain most of their strength, even after long exposure to extremely high temperatures and are the only material suitable for turbine sections of jet engines. Nickel-based super alloys have some characteristics that are responsible for their poor machinability [6,7]. They have an austenitic matrix, and as with stainless steels, they work harden rapidly during machining.…”

Artificial neural network and regression-based models for prediction of surface roughness during turning of red brass (C23000)

“…Surface roughness was found to be influenced by the feed rate during the turning of mild steel with coated carbide tools using RSM [3]. Depth of cut was found to have an insignificant effect on the surface roughness during turning of AISI P20 using CVD and PVD coated carbide tools [4,[12][13][14]. Several techniques have been used for the modelling and optimization of surface roughness during the turning operation, e.g.…”

EXPERIMENTAL STUDY ON MINIMUM QUANTITY LUBRICATION IN END MILLING OF AA6061-T6 USING TiAlN COATED CARBIDE TOOLS

“…A considerable amount of research in the mentioned field has also established its potential application in many practical machining operations [11]. Machining with MQL has been widely applied in machining processes such as drilling [12][13][14], milling [1,6,[15][16][17][18][19][20][21], turning [13,22,23], and MQL grinding [24][25][26][27][28].…”