The demand for high temperature-resistant superalloys such as Inconel 718 is increasing rapidly, as they possess superior mechanical, chemical, and physical properties. Hence, these materials are h...

Machinability of Inconel 718: A critical review on the impact of cutting temperatures

State of the art of tool texturing in machining

Higher cutting zone temperatures are responsible for poor turning process performance during dry machining of Inconel 718 material. In the present work, a novel hybrid surface texture tool under mi...

Effect of novel hybrid texture tool on turning process performance in MQL machining of Inconel 718 superalloy

As widely reported in the literature, the micro-texturing technique has a significant potential to improve the performance of cutting tools by reducing cutting forces, friction, temperature, and tool wear, and further, by improving tribological behavior at the tool-chip and tool-workpiece interface. However, it is also known that the effects of textures on the cutting tool surface strongly depend on the texture geometry and dimensions, and that the application of indiscriminate surface textures to cutting tools often results in adverse effects on cutting performance, indicating that an improved understanding of surface phenomena is required to further develop textured cutting tools. This paper summarizes recent advances in tool surface texturing in metal cutting fields, and continues to describe how the textured surface of a cutting tool influences the deformation fields of the workpiece material, including both primary and secondary shear zones, by means of direct in-situ observation using particle image velocimetry analysis to understand the behavior in the vicinity of the textured surfaces during the cutting process. The experimental results with the textured cutting tool reveal that the effect of the grooved rake face on the cutting force differs depending on the relative position of the microgroove with respect to the undeformed chip thickness. The friction condition and where the texture is located determine the performance of the surface texture. The link between the interface friction and chip flow mode is discussed, and it is demonstrated that surface textures can alter the chip flow mode from a segmented flow with redundant deformation to a steadier homogeneous flow with lower cutting energy.

Direct observations of tribological behavior in cutting with textured cutting tools

This paper focuses on an analysis of tool wear and optimum machining parameter in the induction assisted milling of Inconel 718 using high heat coated carbide and uncoated carbide tools. Thermally assisted machining is an effective machining method for difficult-to-cut materials such as nickel-based superalloy, titanium alloy, etc. Thermally assisted machining is a method of softening the workpiece by preheating using a heat source, such as a laser, plasma or induction heating. Induction assisted milling is a type of thermally assisted machining; induction preheating uses eddy-currents and magnetic force. Induction assisted milling has the advantages of being eco-friendly and economical. Additionally, the preheating temperature can be easily controlled. In this study, the Taguchi method is used to obtain the major parameters for the analysis of cutting force, surface roughness and tool wear of coated and uncoated tools under various machining conditions. Before machining experiments, a finite element analysis is performed to select the effective depth of the cut. The S/N ratio and ANOVA of the cutting force, surface roughness and tool wear are analyzed, and the response optimization method is used to suggest the optimal machining parameters.

https://www.mdpi.com/1996-1944/12/2/233/pdf

A Study on the Optimal Machining Parameters of the Induction Assisted Milling with Inconel 718

Tool-chip adhesion impacts on cutting performance significantly, especially in finish cutting process. To promote cutting tools’ anti-adhesion property, the concave micro-grooves texture (MGT) and convex volcano-like texture (VLT) were fabricated separately on lathe tools’ rake faces by laser surface texturing (LST). Various orientations of MGT and different area densities (9% and 48%) and regions (partial and full) of VLT were considered in textured patterns designing. The following orthogonal cutting experiments, machining of aluminum alloy 5038, analyzed tools’ performances including cutting force, cutting stability, chip shape, rake face adhesion and abrasion. It indicated that under dry finish cutting conditions, MGT contributed to cutting stability and low cutting forces, meanwhile friction and normal force reduced by around 15% and 10%, respectively with a weak correlation to the grooves’ orientation. High density VLT tools, on the other hand, presented an obvious anti-adhesion property. A 5 μm reduction of crater wear’s depth can be observed on textured rake faces after long length cutting and textured rake faces presented half size of BUE regions comparing to the flat tool, however, once the texture morphologies were filled or worn, the anti-adhesion effect could be invalid. The bearing ratio curve was employed to analysis tool-chip contact and durability of textured surfaces contributing to a better understanding of anti-adhesion and enhanced durability of the textured tools.

Experimental Investigation of Concave and Convex Micro-Textures for Improving Anti-Adhesion Property of Cutting Tool in Dry Finish Cutting

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Experimental Investigation of Concave and Convex Micro-Textures for Improving Anti-Adhesion Property of Cutting Tool in Dry Finish Cutting