Performance of PVD-Coated Carbide Tools When Turning Inconel 718 in Dry Machining

Ibrahim, Gusri Akhyar; Haron, Che Hassan Che; Ghani, Jaharah A; Said, Ahmad Yasir Moh.; Yazid, Moh. Zaid Abu

doi:10.1155/2011/790975

Cited by 24 publications

(6 citation statements)

References 11 publications

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“…The continuous process of pulling and tearing of the unstable chips will eventually initiate chipping and will lead to severe fracture and breakage which can be seen in Figure 7. This result is similar to what had been observed by Akhyar Ibrahim et al (2011).…”

Section: Resultssupporting

confidence: 93%

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

Ahmad

Ghani

Haron

2022

ILT

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Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

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Section: Resultssupporting

confidence: 93%

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

Ahmad

Ghani

Haron

2022

ILT

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“…Extensive researches have been made on TiAlN hard coatings in cutting Inconel 718, as this material possesses high hardness, high wear resistance, high high-temperature stability, and superior mechanical properties [5][6][7]. With Si added, TiAlSiN coatings have better mechanical properties than TiAlN due to the microstructure of TiAlSiN, who's crystalline nc-TiAlN phases are wrapped in amorphous a-Si3N4 phase at nanometer scale [8,9].…”

Section: Introductionmentioning

confidence: 99%

The Performance of TiAlSiN Coated Cemented Carbide Tools Enhanced by Inserting Ti Interlayers

Han

et al. 2019

Metals

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To enhance the cutting performance of TiAlSiN coated cemented carbide tools by inserting Ti interlayers and to explore their mechanism, TiAlSiN/Ti multilayer coatings with different Ti thicknesses, including 0 nm, 25 nm, 50 nm, 100 nm, and 150 nm, were deposited onto cemented carbide (WC-10 wt%, Co) substrates by high power impulse magnetron sputtering (HiPIMS). The microstructure, hardness, grain orientation, residual stress, adhesion, and toughness of those coatings were measured, and the cutting performance against Inconel 718 was analyzed. Meanwhile, finite element method (FEM) indentation simulations were performed to gain detailed insight into the effects of Ti interlayer thickness on mechanical properties of TiAlSiN/Ti multilayer coatings. Results demonstrated that mechanical properties of TiAlSiN multilayer coatings were significantly changed after the Ti interlayer was introduced, and the multilayer coating #M2 with 25 nm Ti layer showed the excellent toughness and adhesion without sacrificing hardness too much. As Ti interlayer thickness increased, both toughness and adhesion decrease owing to the plastic mismatch between individual layers, and these changes were discussed detailedly with finite element method. Moreover, the result of the cutting experiment also revealed that the tool flank wear Vb can be reduced by the multilayer structure. This improvement is believed to be due to the increasing toughness, which alleviated the damage caused by the continuous impact load of hard phases generated by Inconel 718 during cutting.

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“…At the lower nose radius, hard particles in the work piece result in the tool abrasion over the rake surface. The delamination tool wear, during the lower cutting speed, causes pressure welding of burr on the rake surface, as explained by Ibrahim et al [35]. Further machining process aids in burr removal and thus chipping of coating initiates on the tool material.…”

Section: Resultsmentioning

confidence: 99%

Effect of nose radius on the chip morphology, cutting force and tool wear during dry turning of Inconel 718

Rao¹

2023

Tribology - Materials, Surfaces & Interfaces

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The machinability studies for the Inconel 718 alloy with the coated cemented carbide cutting tool having 0.4 and 1.2 mm nose radius, varying cutting speeds (65, 81, 95 and 106 m/min) with a constant feed rate of (0.15 mm/rev) and a depth of cut (0.2 mm) were conducted. The cutting force decreases with the increase in cutting speed due to the thermal softening of the work surface at a high temperature. With the increase in nose radius a decrease in the cutting force is observed due to the increase in the cutting edge of the tool. The formation of residual stress has a profound effect on the change in the tool morphology during the machining of the alloy. Furthermore, the chip analysis in terms of chip morphology is carried out in detail. The detailed tool fracture studies are conducted and are explained for the various machining processes.

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Performance of PVD-Coated Carbide Tools When Turning Inconel 718 in Dry Machining

Cited by 24 publications

References 11 publications

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

The Performance of TiAlSiN Coated Cemented Carbide Tools Enhanced by Inserting Ti Interlayers

Effect of nose radius on the chip morphology, cutting force and tool wear during dry turning of Inconel 718

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