Investigating tool performance and wear when simulating bandsawing of nickel-based superalloy under interrupted orthogonal turning condition

Abstract

The manufacturing industries still face the most challenging job at hand to machine Nickelbased superalloy, Inconel 718, efficiently and economically. In contrast to the extensive research efforts in secondary machining processes such as turning, milling and drilling, very little or no attention is paid on bandsawing of Inconel 718. The paper presents an experimental investigation of machining Inconel 718 using carbide tipped bandsaw teeth in a custom made experimental facility. Cutting forces were measured during the bandsawing operation using a dynamometer and the wear modes and mechanisms in the bandsaw teeth were investigated in a Scanning Electron Microscope (SEM). Three different feeds or depths of cut (10 μm, 20 μm and 30 μm) were employed with a cutting speed of 30 m/min during the machining tests. At smaller feed or depth of cut (10 μm), abrasive wear, adhesive wear and some degree of plastic deformation were identified as the governing mechanisms of tool wear. The higher depth of cut (30 μm) could cause cracking, chipping or premature failure of the carbide tip in bandsaw tooth. Strong welding of workpiece material to the cutting edge formed a built-up-edge (BUE), which would impair the bandsawability due to the modification of the cutting edge. The higher depth of cut significantly improved the machining performance due to the reduction in specific cutting energy. However, it was not recommended to apply higher depth of cut as there were obvious possibilities of premature tooth failure. Machining force and specific cutting energy results along with chip characteristics were correlated with the tool performance and tool wear. The results of this investigation would be helpful for bandsaw manufacturers and end users to get a fundamental understanding of the bandsawability of Inocnel 718 with the carbide tipped bandsaw.

Study of the effect of surface laser texture on tribological properties of cemented carbide materials

“…1 The above characteristics of titanium alloys have significant effects on the tool life, tool consumption and wear resistance of the tool surface. 2,3 At present, many scholars have shown great interest in improving the friction characteristics between the tool and the workpiece (titanium alloys) by changing the surface morphology of the tool. 4 Meanwhile, a few researchers found that great efforts can be made by laser processing technology to improve the friction properties of the surface texture existence 5,6 and the micro-textures.…”

A Comparative Sustainability Assessment of Cutting Fluids Usage in Band Sawing

“…[22] experimentally studied the effects of coatings, tool tip material while bandsawing different work piece material without considering the usage of cutting fluid. Other studies that reported usage of the cutting fluid while cutting materials such as Ti-7, Inconel 718, and medium carbon steels, did not evaluate the effect of the cutting fluids [23][24][25][26]. However, the recent studies by Rakurty et al have shown that the cutting fluid amount, type, and workpiece geometry effects the performance of the band saw blade [10,11].…”

Experimental study on ultra-precision grinding characteristics of WC-Ni hard metals

“…Therefore, they are extensively suitable for a variety of industrial applications such as cutting tools, mining bits, sandblasting nozzles, molds, mechanical seals, and pump valves. [4][5][6] Generally, hard metal products for mining and construction applications are subjected to intensive abrasive wear, high impact grade, and severe thermal and mechanical loading. 7 Hard metals for cutting tools are focused on their excellent wear resistance, high hardness, and flexural and compression strength.…”