Investigation of Modified Cutting Insert with Forced Coolant Application in Machining of Alloy 718

Alagan, Nageswaran Tamil; Beňo, Tomáš; Wretland, Anders

doi:10.1016/j.procir.2016.02.236

Cited by 17 publications

(18 citation statements)

References 10 publications

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“…As such, development of the milling process of difficult to machine materials has either focused on improving the properties of the insert tool material to withstand the cutting conditions or to increase the cutting speeds [5]. Development has also been devoted to improve the heat dissipation in the cutting zone by redesign of insert geometry and thereby enabling increased MRR [6].…”

Section: Traditional Machining Conceptsmentioning

confidence: 99%

Surface integrity after post processing of EDM processed Inconel 718 shaft

Holmberg

Wretland

Berglund

et al. 2017

Int J Adv Manuf Technol

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Electrical discharge machining (EDM) is considered as an efficient alternative to conventional material removal concepts that allows for much higher material removal rates. However, EDM generates unwanted features such as re-cast layer (RCL), tensile residual stresses and a rough surface. In order to recover the surface integrity, different post processes has been compared: high-pressure water jet (HPWJ), grit blasting (GB) and shot peening (SP). Surface integrity has been evaluated regarding microstructure, residual stresses, chemical content and surface roughness. The results showed that a combination of two post processes is required in order to restore an EDM processed surface of discontinuous islands of RCL. HPWJ was superior for removing RCL closely followed by grit blasting. However, grit blasting showed embedded grit blasting abrasive into the surface. Regarding surface roughness, it was shown that both grit blasting and HPWJ caused a roughening of the surface topography while shot peening generates a comparably smoother surface. All three post processes showed compressive residual stresses in the surface where shot peening generated the highest amplitude and penetration depths. However, the microstructure close to the surface revealed that shot peening had generated cracks parallel to the surface. The results strongly state how important it is to evaluate the surface at each of the different subsequent process steps in order to avoid initiation of cracks.

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Section: Traditional Machining Conceptsmentioning

confidence: 99%

Surface integrity after post processing of EDM processed Inconel 718 shaft

Holmberg

Wretland

Berglund

et al. 2017

Int J Adv Manuf Technol

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“…The flank wear profile of the Gen I insert was peak shaped, while the flank wear profile was more of a bell shaped for the Gen II insert [10]. The profiles were consistent for all cutting speeds and SCL’s for Gen I and Gen II inserts.…”

Section: Tool Wear Analysismentioning

confidence: 97%

“…When the cutting speed was further increased to 90 m/min, the Gen II insert had a 28% reduced flank wear compared to the Gen I insert [10]. Both the Gen I and Gen II inserts had extensive flank wear of more than 1 mm.…”

Section: Tool Wear Analysismentioning

confidence: 99%

“…Results from the flank wear analysis were ambiguous [9,10]. To clarify, the volumetric analysis was performed on the cutting tools seen in Figure 17.…”

Section: Tool Wear Analysismentioning

confidence: 99%

“…During the last years, the investigations have been directed towards using textures in combination with high-pressure coolant to improve the heat transfer rate for improving tool life. Tamil Alagan et al have published works on surface featured inserts with high-pressure coolant for improved heat dissipation from the cutting zone [9,10,11]. Fang and Obikawa [12], investigated on five types of textures on the flank face in combination with high-pressure coolant.…”

Section: Introductionmentioning

confidence: 99%

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Influence of Surface Features for Increased Heat Dissipation on Tool Wear

et al. 2018

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The critical problems faced during the machining process of heat resistant superalloys, (HRSA), is the concentration of heat in the cutting zone and the difficulty in dissipating it. The concentrated heat in the cutting zone has a negative influence on the tool life and surface quality of the machined surface, which in turn, contributes to higher manufacturing costs. This paper investigates improved heat dissipation from the cutting zone on the tool wear through surface features on the cutting tools. Firstly, the objective was to increase the available surface area in high temperature regions of the cutting tool. Secondly, multiple surface features were fabricated for the purpose of acting as channels in the rake face to create better access for the coolant to the proximity of the cutting edge. The purpose was thereby to improve the cooling of the cutting edge itself, which exhibits the highest temperature during machining. These modified inserts were experimentally investigated in face turning of Alloy 718 with high-pressure coolant. Overall results exhibited that surface featured inserts decreased flank wear, abrasion of the flank face, cutting edge deterioration and crater wear probably due to better heat dissipation from the cutting zone.

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