Effect of cutting speed on the carbide cutting tool in milling Inconel 718 alloy
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Mohd. Shahir Kasim Department of Process, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 75450 Melaka, Malaysia (Received 30 September 2015; accepted 13 November 2015)
Tribology is a phenomenon concerning the relative motion between at least two amalgamating surfaces. In the machining process, surface roughness is the most important element for studying this occurrence, which contributes to the evaluation of part quality. This paper will provide detailed analysis for better understanding of tribological during the machining process of Inconel 718 alloy using a multi-layer TiAlN/AlCrN-coated carbide ball end inserted in dry cutting condition. The analysis focused on the relationship of tool wear with cutting temperature, cutting force, and surface integrity. Results found that the cutting temperature increased around 7.5% and surface roughness of machined surface improved about 10.3% when the cutting speed increased. Flaking at the rake face and notching at the flank face were determined as the main tool failures during milling Inconel 718. Furthermore, high friction between the tool–workpiece interfaces during machining was due to the build-up edge (BUE) formation that causes an alteration in microstructure at machine surface.
I. INTRODUCTION
Nickel based alloy also known as a group of superalloys, is widely used for various parts of components and structures for aerospace, marine, and automobile industries, as well as chemical processing etc. Specific properties such as high resistance to creep, high toughness, and strength at elevated temperature, good resistance to chemical degradation, and wear have made this alloy well suited for service in extreme environments, especially for high temperature application. However, its low thermal conductivity and specific heat volume leads to high cutting temperature and its superior mechanical properties have also resulted in high cutting force. In addition, chips are easy to stick at the tool tip and tend to generate build up edge (BUE), which results in a rapid tool wear.1 Thus, nickel based alloy normally refers to a ‘difficult-to-cut’ material in a machining context.2 In the case of milling process, it is also known as an interrupted cutting process, where the direction of the cutting force changes due to the tool rotation, and as the tooth enters and leaves the workpiece for every cutting pass.3,4 This resulted in various wear mechanisms, cutting temperature, and dynamic stability compared to
the continuous cutting process. It is claimed that in cutting superalloy materials, the low thermal conductivity, combined with a high chemical reactivity and adhesion with tool materials5 means that temperature at the tool tip area rapidly increases, and drastically affects tool wear.6,7 Thus, an effective high speed cutting application for these types of alloys cannot be optimized due to the extremely high thermal loads applied on the tool material. Based on this issue, most of the superalloy material still being machined under flooding co
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