Notch wear prediction model in turning of Inconel 718 with ceramic tools considering the influence of work hardened layer

Zhuang, Kejia; Zhu, Dahu; Zhang, Xiaoming; Ding, Han

doi:10.1016/j.wear.2014.02.007

Cited by 92 publications

(38 citation statements)

References 41 publications

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“…2. Stahl et al [25] noted that the work hardening of the outer surface layer of the workpiece leads to notch wear and has been regarded as the main causation of notch wear, and a quantitative study has been investigated by Zhuang et al [26].…”

Section: (B) Notch Wearmentioning

confidence: 99%

“…The number of dislocations can be increased with the plastic deformation as well as cutting heat, which results in the increase in resistance to further occurrence of deformations [25]. Then the hardened surface of material can lead to severe tool wear, such as notch wear [26]. Micro-hardness tests are carried out for the three machining conditions with a force load of 20 gf.…”

Section: Surface Integrity Of Machined Surfacementioning

confidence: 99%

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Employing preheating- and cooling-assisted technologies in machining of Inconel 718 with ceramic cutting tools: towards reducing tool wear and improving surface integrity

Zhuang

Zhang

Zhu

et al. 2015

Int J Adv Manuf Technol

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This paper is motivated by the fact that machining of Inconel 718 involves rapid tool wear and poor surface integrity. We investigate the performance of ceramic cutting inserts in turning of Inconel 718 by virtue of two different assisted machining conditions, plasma preheating-and cryogenic cooling-assisted technologies. The plasma nozzle placed in front of the cutting zone is used to soften the materials before machining. The liquid nitrogen flow located in the cutting area is used to reduce the cutting temperatures in the contact area. The cutting experiments are set for reducing tool wear and improving surface integrity, including surface roughness and micro-hardness beneath workpiece surface. With these two assisted techniques, the tool wear including flank wear and notch wear and the surface microstructure including surface roughness and micro-hardness are assessed and compared with conventional machining. Tool wear reduction and surface integrity improvement can be obtained with these two assisted technologies in turning of Inconel 718 with ceramic cutting inserts. The main causation of notch wear of the ceramic cutting inserts may be the hardened layer beneath the surface. By comparing these two assisted cutting techniques with opposite effects on the cutting tool and workpiece, it has been found that the surface roughness is reduced by 50 %, the micro-hardness is smaller, and the tool life is extended up to more than 40 % over conventional machining.

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Section: (B) Notch Wearmentioning

confidence: 99%

Section: Surface Integrity Of Machined Surfacementioning

confidence: 99%

Employing preheating- and cooling-assisted technologies in machining of Inconel 718 with ceramic cutting tools: towards reducing tool wear and improving surface integrity

Zhuang

Zhang

Zhu

et al. 2015

Int J Adv Manuf Technol

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“…However, Zhuang et al (2014) concluded that the tool failure having another form. Certainly, the main failure modes of ceramic cutting tools during machining of Inconel 718 are notch wear and flank wear.…”

Section: Introductionmentioning

confidence: 99%

Quality-productivity decision making when turning of Inconel 718 aerospace alloy: A response surface methodology approach

Tebassi¹,

Yallese²,

Belhadi³

et al. 2017

10.5267/j.ijiec

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Inconel 718 is among difficult to machine materials because of its abrasiveness and high strength even at high temperature. This alloy is mainly used in aircraft and aerospace industries. Therefore, it is very important to reveal and evaluate cutting tools behavior during machining of this kind of alloy. The experimental study presented in this research work has been carried out in order to elucidate surface roughness and productivity mathematical models during turning of Inconel 718 superalloy (35 HRC) with SiC Whisker ceramic tool at various cutting parameters (depth of cut, feed rate, cutting speed and radius nose). A small central composite design (SCCD) including 16 basics runs replicated three times (48 runs), was adopted and graphically evaluated using Fraction of design space (FDS) graph, completed by a statistical analysis of variance (ANOVA). Mathematical models for surface roughness and productivity were developed and normality was improved using the Box-Cox transformation. Results show that surface roughness criterion Ra was mainly influenced by cutting speed, radius nose and feed rate, and that the depth of cut had major effect on productivity. Finally, ranges of optimized cutting conditions were proposed for serial industrial production. Industrial benefit was illustrated in terms of high surface quality accompanied with high productivity. Indeed, results show that the use of optimal cutting condition had an industrial benefit to 46.9 % as an improvement in surface quality Ra and 160.54 % in productivity MRR.

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“…The strong strain hardening tendency results in a significant hardened layer on machined surfaces, the extent of which, depends on the cutting parameters such as speed, feed rate, tool material and geometry [3,4]. The hardened surface, which enters into the cutting zone of the subsequent cuts, is one of the most interesting causes, among those suggested, for notch wear formation [2,5,6]. This leads to the conclusion that the influence of prior plastic deformation on the machining process seems to be of interest.…”

Section: Introductionmentioning

confidence: 99%

Influence of Deformed Surface Layer When Machining Wrought Alloy 718 in an Annealed and in a Pre-Strained Condition

Cedergren¹,

Sjoberg²,

Johansson³

2014

8th International Symposium on Superalloy 718 and Derivatives (2014)

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Superalloys are difficult to cut, mainly due to their preserved strength at elevated temperatures and their exceptional work hardening, where the latter results in a deformed layer on the machined surface. The thickness and degree of deformation of this layer depends on several parameters, such as cutting speed, uncut chip thickness, tool material and edge geometry. This layer enters the cutting zone of subsequent revolutions in turning or in milling. Under certain circumstances, as when the uncut chip thickness is small, all deformation at subsequent machining takes place within the deformed layer. The same phenomenon may occur at the outer edge of the cutting zone where the unrestricted material flow leads to burr formation. The deformed layer at the outer edge is suggested as the cause for notch wear often found when machining Superalloys. In this paper the effect of deformed layer on machining is examined through controlled experiments on the material in to different states of strain; in the annealed state without any remaining strain and with a substantial amount introduced by tensile straining. The results showed that cutting forces were reduced when pre-straining the material. Tool wear was similar in both materials, with large scatter due to built-up edge formation.

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Notch wear prediction model in turning of Inconel 718 with ceramic tools considering the influence of work hardened layer

Cited by 92 publications

References 41 publications

Employing preheating- and cooling-assisted technologies in machining of Inconel 718 with ceramic cutting tools: towards reducing tool wear and improving surface integrity

Employing preheating- and cooling-assisted technologies in machining of Inconel 718 with ceramic cutting tools: towards reducing tool wear and improving surface integrity

Quality-productivity decision making when turning of Inconel 718 aerospace alloy: A response surface methodology approach

Influence of Deformed Surface Layer When Machining Wrought Alloy 718 in an Annealed and in a Pre-Strained Condition

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