Experimental Investigation on Sialon Ceramic Inserts for Ultra-high-speed Milling of Inconel 718

A series of milling aerospace material Inconel 718 experiments were conducted with a sialon ceramic tool to investigate chip evolution, cutting force, and tool wear at different cutting speeds. Round inserts were used at ultra-high-speeds under dry cutting conditions. A scanning electron microscopy and an optical microscope were used to observe the worn surfaces and to reveal the wear mechanisms of the inserts. The experiment results showed that the macroscopic shape of the chips was small scraps and fan-shaped. With the increase in the cutting speed, the plastic deformation of the chips was increasingly serious. The minimal average cutting forces were obtained at vc = 700 m/min. The rise of cutting temperature was resulted from the increase in cutting deformation work and friction work with cutting speed. The combined effect of thermal stress and mechanical stress contributed to the tool chipping, flaking, microcrack propagation, abrasion, and adhesion which were the primary reasons of the sialon ceramic tool wear.

[1]  M. Nicolescu,et al.  Influence of Tool Materials on Machinability of Titanium- and Nickel-Based Alloys: A Review , 2014 .

[2]  Zhanqiang Liu,et al.  Deformation-phase transformation coupling mechanism of white layer formation in high speed machining of FGH95 Ni-based superalloy , 2014 .

[3]  Ming Chen,et al.  EXPERIMENTAL INVESTIGATION ON SURFACE INTEGRITY OF END MILLING NICKEL-BASED ALLOY— INCONEL 718 , 2014 .

[4]  Yi Wan,et al.  Analytical modeling and experimental investigation of tool and workpiece temperatures for interrupted cutting 1045 steel by inverse heat conduction method , 2013 .

[5]  D. Gao,et al.  Cutting Parameter Optimization Based on Optimal Cutting Temperature in Machining Inconel718 , 2012 .

[6]  L. Vijayaraghavan,et al.  Some Investigations on High Speed Dry Machining of Aerospace Material Inconel 718 Using Multicoated Carbide Inserts , 2012 .

[7]  Inderpreet Singh Ahuja,et al.  Influence of cutting parameters on tool wear and surface roughness in hard turning of AISI H11 tool steel using ceramic tools , 2012 .

[8]  Jun Zhao,et al.  Friction and wear behaviors of Sialon–Si3N4 graded nano-composite ceramic materials in sliding wear tests and in cutting processes , 2012 .

[9]  Liu Zhanqiang,et al.  Characteristics of chip evolution with elevating cutting speed from low to very high , 2012 .

[10]  Jun Zhao,et al.  Ultra High Speed Turning of Inconel 718 with Sialon Ceramic Tools , 2010 .

[11]  Yuebin Guo,et al.  SURFACE INTEGRITY CHARACTERIZATION AND PREDICTION IN MACHINING OF HARDENED AND DIFFICULT-TO-MACHINE ALLOYS: A STATE-OF-ART RESEARCH REVIEW AND ANALYSIS , 2009 .

[12]  Suhas S. Joshi,et al.  An analytical model to predict specific shear energy in high-speed turning of Inconel 718 , 2009 .

[13]  L. Vijayaraghavan,et al.  A Study on the Parameters in High-Speed Turning of Superalloy Inconel 718 , 2009 .

[14]  Suhas S. Joshi,et al.  Effect of machining parameters and cutting edge geometry on surface integrity of high-speed turned Inconel 718 , 2008 .

[15]  Gérard Poulachon,et al.  Tool-life and wear mechanisms of CBN tools in machining of Inconel 718 , 2007 .

[16]  Muammer Nalbant,et al.  The effect of cutting speed and cutting tool geometry on machinability properties of nickel-base Inconel 718 super alloys , 2007 .

[17]  Muammer Nalbant,et al.  The effects of cutting speed on tool wear and tool life when machining Inconel 718 with ceramic tools , 2007 .

[18]  XiaoQi Chen,et al.  An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts , 2006 .

[19]  J. M. Longbottom,et al.  A review of research related to Salomon's hypothesis on cutting speeds and temperatures , 2006 .

[20]  Martin Bäker,et al.  Finite element simulation of high-speed cutting forces , 2006 .