Tool wear progression of SiAlON ceramic end mills in five-axis high-feed rough machining of an Inconel 718 BLISK

Zimmermann, Richard; Welling, D.; Venek, Tommy; Ganser, Philipp; Bergs, Thomas

doi:10.1016/j.procir.2021.02.003

Cited by 14 publications

(5 citation statements)

References 4 publications

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“…This was to be expected; however, the increase was quite significant, meaning that after only a short distance, the tools suffered a lot of flank wear. This was due to the properties of Inconel 718 causing high abrasive damage that led to tool chipping [51]. Additionally, the values that were obtained for tests conducted at 100 m/min were slightly lower than those obtained at a 125 m/min cutting speed.…”

Section: Wear Measurements and Characterizationmentioning

confidence: 85%

Wear Behavior Phenomena of TiN/TiAlN HiPIMS PVD-Coated Tools on Milling Inconel 718

Sousa

Fernandes

Silva

et al. 2023

Metals

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Due to Inconel 718’s high mechanical properties, even at higher temperatures, tendency to work-harden, and low thermal conductivity, this alloy is considered hard to machine. The machining of this alloy causes high amounts of tool wear, leading to its premature failure. There seems to be a gap in the literature, particularly regarding milling and finishing operations applied to Inconel 718 parts. In the present study, the wear behavior of multilayered PVD HiPIMS (High-power impulse magnetron sputtering)-coated TiN/TiAlN end-mills used for finishing operations on Inconel 718 is evaluated, aiming to establish/expand the understanding of the wear behavior of coated tools when machining these alloys. Different machining parameters, such as cutting speed, cutting length, and feed per tooth, are tested, evaluating the influence of these parameters’ variations on tool wear. The sustained wear was evaluated using SEM (Scanning electron microscope) analysis, characterizing the tools’ wear and identifying the predominant wear mechanisms. The machined surface was also evaluated after each machining test, establishing a relationship between the tools’ wear and production quality. It was noticed that the feed rate parameter exerted the most influence on the tools’ production quality, while the cutting speed mostly impacted the tools’ wear. The main wear mechanisms identified were abrasion, material adhesion, cratering, and adhesive wear. The findings of this study might prove useful for future research conducted on this topic, either optimization studies or studies on the simulation of the milling of Inconel alloys, such as the one presented here.

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Section: Wear Measurements and Characterizationmentioning

confidence: 85%

Wear Behavior Phenomena of TiN/TiAlN HiPIMS PVD-Coated Tools on Milling Inconel 718

Sousa

Fernandes

Silva

et al. 2023

Metals

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“…When increasing from 5 m to 15 m, the resulting VB3 is higher. This is due to the properties of Inconel 718, such as the thermomechanical tool load, which generates high abrasive damage [65]. However, no clear influence of the f z parameter is observed.…”

Section: Wear Measurements and Characterisationmentioning

confidence: 98%

“…This is not commonly observed, as the tendency is for SR to decrease as this parameter increases [64]. This phenomenon probably occurred because Inconel 718 is a material that is difficult to machine, the amount of wear suffered at these v c s was high, and high abrasive wear was usually observed, which can lead to cutting tool chipping [65]. The only case in which it was observed that by increasing the v c the R a was lower was for 100% f z , with a L cut = 15 m, when increasing the v c from 100 m/min to 125 m/min.…”

Section: Roughness Analysis Of the Machined Surfacementioning

confidence: 98%

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Investigations on the Surface Integrity and Wear Mechanisms of TiAlYN-Coated Tools in Inconel 718 Milling Operations

Silva,

Sebbe,

Costa

et al. 2024

Materials

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Inconel 718 is a Ni superalloy with superior mechanical properties, even at high temperatures. However, due to its high hardness and low thermal conductivity, it is considered a difficult-to-machine material. This material is widely used in applications that require good dimensional stability, making the milling process the most used in machining this alloy. The wear resulting from this process and the quality of the machined surface are still challenging factors when it comes to Inconel 718. TiAlN-based coating has been used on cutting tools with Yttrium as a doping element to improve the process performance. Based on this, this work evaluated the machined surface integrity and wear resistance of cutting tools coated using Physical Vapor Deposition (PVD) HiPIMS with TiAlYN in the end milling of Inconel 718, varying the process parameters such as cutting speed (vc), feed per tooth (fz), and cutting length (Lcut). It was verified that the Lcut is the parameter that exerts the most significant influence since, even at small distances, Inconel 718 already generates high tool wear (TW). Furthermore, the main wear mechanisms were abrasive and adhesive wear, with the development of a built-up edge (BUE) under a125 m/min feed rate (f) and a Lcut = 15 m. Chipping, cracking, and delamination of the coating were also observed, indicating a lack of adhesion between the coating and the substrate, suggesting the need for a good interlayer or the adjustment of the PVD parameters.

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“…These features make high feed milling a competitive approach especially to the machining of hard-to-machine materials. Zimmermann et al [17] investigated the wear of SiAlON ceramic mill tool in the high feed milling of Inconel 718 and vitri cated the improvement in the machining e ciency in the machining of high-pressure compressor blisk. Liu et al[18] studied the in uence of tool geometry on the surface integrity in the high feed milling of a slender stainless steel X2CrNiMo17-12-2, due to the high thermal stress inhomogeneous microstructure deformation is found in the rim zone.…”

Section: Introductionmentioning

confidence: 99%

Investigation on the high-feed milling of M28

Jiang,

Yang,

Tian

et al. 2023

Int J Adv Manuf Technol

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The outstanding combination of high strength, fracture toughness and low mass makes the metastable β titanium alloy an ideal material for aviation application. Machining of the metastable β titanium alloy remains a challenge due to their poor machinability. In this study, the high feed milling of a novel metastable β titanium alloy M28 is investigated to evaluate the performance of a potential highe ciency-machining approach for the next generation titanium alloy and promote the understanding of high feed milling. The cutting force and the wear mechanism of carbide tool coated with TiAlN-Al 2 O 3 are investigated as well as the in uence of high feed on machined surface microstructures and microhardness. Due to the chip thinning effect of high feed milling, a proper high feed maintains a su cient chip thickness to prevent the ploughing. Cutting edge degeneration induced by the carbide matrix fracture accelerates the tool wear. Mechanical stress induced cracks lead to the uneven delamination of the TiAlN-Al 2 O 3 coating. Slight effect of high feed can be found on the microstructures and microhardness of the machined surface. While the tool wear leads to signi cant grain fragmentation and distortion at the surface. Since no white layer is found in the cutting of M28, high feed milling shows the advantage of preventing the heat induced surface injury.

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Tool wear progression of SiAlON ceramic end mills in five-axis high-feed rough machining of an Inconel 718 BLISK

Cited by 14 publications

References 4 publications

Wear Behavior Phenomena of TiN/TiAlN HiPIMS PVD-Coated Tools on Milling Inconel 718

Wear Behavior Phenomena of TiN/TiAlN HiPIMS PVD-Coated Tools on Milling Inconel 718

Investigations on the Surface Integrity and Wear Mechanisms of TiAlYN-Coated Tools in Inconel 718 Milling Operations

Investigation on the high-feed milling of M28

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