Wear Mechanisms and Notch Formation of Whisker-Reinforced Alumina and Sialon Ceramic Tools during High-Speed Turning of Inconel 718

Xue, Chao; Wang, Dong; Zhang, Jingjing

doi:10.3390/ma15113860

Cited by 14 publications

(7 citation statements)

References 27 publications

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“…This tool nose notching at the depth of cut is located at the intersection between the cutting edge and the machined surface, which is a common failure mode when machining nickel-based alloys. Notch formation results from a combination of aggressive cutting conditions involved during the machining process of Ni-based alloys: high temperature, elevated strength, and strain hardening of the workpiece maintained at high temperature and the abrasive chips [42].…”

Section: Tool Wearmentioning

confidence: 99%

On the Influence of Binder Material in PCBN Cutting Tools for Turning Operations of Inconel 718

Matos

Silva

Sousa

et al. 2023

Metals

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Inconel 718 is a highly valued material in the aerospace and nuclear industries due to the fact of its exceptional properties. However, the processing of this material is quite difficult, especially through machining processes. Machining this material results in rapid tool wear, even when low material removal rates are considered. In this study, instrumented turning experiments were employed to evaluate the machinability of Inconel 718 alloy using PCBN tools while assessing the usage of two distinct binder phases, TiN and TiC, for those cutting tools. It was found that the tool life was highly sensitive to the cutting speeds but also affected by the workpiece mechanical properties. At lower cutting speeds, notch wear significantly impacted the tool integrity, whereas at higher cutting speeds, flank wear was the primary failure mode of the tool. The flank wear of the tools with TiN-based binder outperformed TiC by almost 30%, presenting a more consistent behavior when machining.

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Section: Tool Wearmentioning

confidence: 99%

On the Influence of Binder Material in PCBN Cutting Tools for Turning Operations of Inconel 718

Matos

Silva

Sousa

et al. 2023

Metals

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“…In order to process difficult-to-cut materials commonly used in the automobile, aircraft and astronautic manufacturing industries (such as hardened steel, nickel-based and titanium alloys, etc. ), advanced ceramic tools must have high mechanical and thermal properties [ 1 , 2 , 3 , 4 , 5 , 6 ]. For example, at ambient temperature, the flexural strength, fracture toughness, and Vickers hardness of Al 2 O 3 /TiC micro–nano-composite ceramic tool material were 916 MPa, 8.3 MPa·m 1/2 and 18 Gpa, respectively, and still maintained a high flexural strength value (about 390 MPa) at 1200 °C.…”

Section: Introductionmentioning

confidence: 99%

Preparation of In Situ Growth Multiscale β-Sialon Grain-Reinforced Al2O3-Based Composite Ceramic Tool Materials

et al. 2023

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A kind of multiscale β-sialon grain-reinforced Al2O3 matrix composite ceramic tool material, named ASN, was prepared and studied. For the ASN, β-sialon (molecular formula: Si4Al2O2N6) was synthesized in situ by a hot-pressing and solid-solution reaction process. A total of six samples were prepared at varying sintering temperatures and holding times under vacuum conditions. The solid solution reaction mechanism of β-sialon, the phase composition, mechanical properties, microstructure, and strengthening and toughening mechanisms of the composite ASN were investigated. As a result, within the experimental parameters, an optimal ASN tool material was obtained under a pressure of 32 MPa and at a temperature of 1550 °C for 20 min. The tested mechanical properties of the optimal sample were as follows: flexural strength 997 ± 59 MPa, fracture toughness 6.4 ± 0.3 MPa·m1/2, Vickers hardness 18.2 ± 0.4 GPa, and relative density 98.1 ± 0.2%. According to crystal defect theory, the solid solution reaction mechanism of in-situ-synthesized β-sialon in an Al2O3 matrix involves a double mechanism of unequivalence (or hetero-valence) and interstitial filling. The multiscale β-sialon grains mainly consisted of four grains, which were elongated β-sialon grains with a diameter of 0.3–0.4 μm and an aspect ratio of 6–9, elongated β-sialon grains with a diameter of 70 nm and an aspect ratio of 10, β-sialon whiskers with a diameter of 0.2 μm and an aspect ratio of 12–15, and intragranular β-sialon whiskers with a diameter of 70 nm. The mechanical properties were improved due to strengthening and toughening mechanisms, such as mixed structure mode (intergranular and transgranular), elongated grain pullout, interface bonding, crack reflection, pinning, and bridging.

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“…Anti-friction, thermal barrier, and tool life improve with increasing Al content. Xue et al [33] investigated the wear mechanisms of SiC whisker-reinforced alumina and Sialon. The results showed that the wear process of SiC whisker-reinforced alumina was dominated by notch wear, while flank wear, characterized by ridges and grooves, was the main wear mode for Sialon.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Dry Turning of Inconel 601 Alloy Based on Surface Roughness, Tool Wear, and Material Removal Rate

Jovicic

Milosević

Kanović

et al. 2023

Metals

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In this work, the dry turning of Inconel 601 alloy in a dry environment with PVD-coated cutting inserts was studied. Turning was performed at various cutting speeds, feeds, insert shapes, corner radii, rake angles, and approach angles. After machining, arithmetic mean surface roughness (Ra) and flank wear (VB) were measured, and the material removal rate was also calculated (MRR). An analysis of variance (ANOVA) was performed to determine the effects of the turning input parameters. For the measured values, the turning process was modeled using an artificial neural network (ANN). Based on the obtained model, the process parameters were optimized using a genetic algorithm (GA). The objective function was to simultaneously minimize Ra and VB and maximize MRR. The accuracy of the model and the optimal values were further validated by confirmation experiments. The maximum percentage errors, which are less than 2%, indicate the possibility of practical implementation of the hybrid approach for modeling and optimization of dry turning of Inconel 601 alloy.

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Wear Mechanisms and Notch Formation of Whisker-Reinforced Alumina and Sialon Ceramic Tools during High-Speed Turning of Inconel 718

Cited by 14 publications

References 27 publications

On the Influence of Binder Material in PCBN Cutting Tools for Turning Operations of Inconel 718

On the Influence of Binder Material in PCBN Cutting Tools for Turning Operations of Inconel 718

Preparation of In Situ Growth Multiscale β-Sialon Grain-Reinforced Al2O3-Based Composite Ceramic Tool Materials

Optimization of Dry Turning of Inconel 601 Alloy Based on Surface Roughness, Tool Wear, and Material Removal Rate

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