A New Approach of Wear Mechanism Map in Turning Inconel718 with PVD-Coated Inserts Using Advanced Techniques
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RESEARCH PAPER
A New Approach of Wear Mechanism Map in Turning Inconel718 with PVD‑Coated Inserts Using Advanced Techniques B. Movahedi1 · R. Mokhtari Homami1 · S. Akhavan2 Received: 12 January 2018 / Accepted: 26 July 2019 © Shiraz University 2019
Abstract In this paper, the relationship between the cutting conditions and the wear mechanisms in turning Inconel718 from both modeling and experiment points of view has been studied. The tool chosen consists of a hard fine-grained WC with 6% Co with TiAlN layer. As a result, the recommended machining conditions with minimal wear would be the selection of a tool with a radius of 1.6 mm and the cutting velocity in the range of 45 to 55 m/min. The optimal variables obtained from artificial neural networks and genetic algorithm are found to be in good agreement with the results of laboratory findings on the wear mechanism map. Also, the results showed that at lower cutting velocities and feed rates, the TiAlN layer acts to prevent the transfer of elements between the tool and workpiece (mild and transient wear zones), causing the turning forces to stabilize over time. However, with an increase in the cutting velocity and feed rate (severe zone), the TiAlN layer breaks off the tool surface resulting in a considerable increase in the friction coefficient, cutting forces, and the adhesive wear. The main reason for this phenomenon is the transfer of elements such as nickel, chrome, and iron to the flank face. Keywords Flank wear · Crater wear · PVD-coated inserts · ANOVA · Modeling · Artificial neural network · Optimizing · Genetic algorithm
1 Introduction Since turning is the basic operation in most production procedures in the industry, the surface finish of turned parts has a larger influence on the quality of the product. Extreme caution must therefore be taken to ensure the surface quality of the part and tool wear during turning. This necessitates a process optimization to specify optimal values of cutting parameters, such as cutting velocity (Vc), feed rate (af), approach angle (X), and nose radius (rɛ), to completely evaluate the performance of tools in turning (Nalbant et al. 2007). Inconel718 is a nickel-based superalloy which is widely used in the aerospace industry due to their excellent material properties such as low density, high heat resistance, good * B. Movahedi [email protected] 1
Department of Nanotechnology Engineering, Faculty of Advanced Sciences and Technologies, University of Isfahan, Isfahan 81746‑73441, Iran
Department of Materials Engineering, Isfahan University of Technology, Isfahan 84156‑83111, Iran
2
mechanical and chemical properties at elevated temperatures, high melting temperatures, and high resistance to thermal fatigue. It contains a niobium age-hardening addition that provides increased strength and corrosion resistance without a decrease in ductility. The alloy has excellent creeprupture strength at temperature up to 700 °C. Therefore, it is widely used in gas turbines, aircraft, rocket motors, spacecraft, nuclear rea
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