Temperature and wear of cutting tools in high-speed machining of Inconel 718 and Ti6Al6V2Sn
TL;DR: In this article, the authors investigated the thermal properties of high-speed machining of Inconel 718 and Ti 6Al 6V 2Sn alloys from a thermal point of view.
About: This article is published in Wear.The article was published on 1997-01-01. It has received 500 citations till now. The article focuses on the topics: Machining & Chip formation.
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TL;DR: In this paper, the authors provide an overview of machining induced surface integrity in titanium and nickel alloys and conclude that further modeling studies are needed to create predictive physics-based models that is in good agreement with reliable experiments.
Abstract: Titanium and nickel alloys represent a significant metal portion of the aircraft structural and engine components. When these critical structural components in aerospace industry are manufactured with the objective to reach high reliability levels, surface integrity is one of the most relevant parameters used for evaluating the quality of finish machined surfaces. The residual stresses and surface alteration (white etch layer and depth of work hardening) induced by machining of titanium alloys and nickel-based alloys are very critical due to safety and sustainability concerns. This review paper provides an overview of machining induced surface integrity in titanium and nickel alloys. There are many different types of surface integrity problems reported in literature, and among these, residual stresses, white layer and work hardening layers, as well as microstructural alterations can be studied in order to improve surface qualities of end products. Many parameters affect the surface quality of workpieces, and cutting speed, feed rate, depth of cut, tool geometry and preparation, tool wear, and workpiece properties are among the most important ones worth to investigate. Experimental and empirical studies as well as analytical and Finite Element modeling based approaches are offered in order to better understand machining induced surface integrity. In the current state-of-the-art however, a comprehensive and systematic modeling approach based on the process physics and applicable to the industrial processes is still missing. It is concluded that further modeling studies are needed to create predictive physics-based models that is in good agreement with reliable experiments, while explaining the effects of many parameters, for machining of titanium alloys and nickel-based alloys.
986 citations
Cites background from "Temperature and wear of cutting too..."
...It is observed that compared to the most famous nickel alloy IN-718, titanium alloy Ti–6Al–6V–2Sn offered considerably higher machinability and lower temperature outcomes [20]....
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...The temperatures created during high-speed machining (endmilling and turning) of IN-718 and titanium alloy 6Al–6V–2Sn were found to play a major role in tool wear, which is a significant factor in surface roughness of materials [1,20]....
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...5Mn [19], Ti–6Al–6V–2Sn (Ti-6-6-2) [20], Ti–5Al–4Mo–2Sn–6Si–2Fe (TA-48) [21], and Ti–6Al–7Nb [22], as shown in Table 1....
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TL;DR: In this paper, the authors proposed a method for machining aeroengine alloys with improved hardness, such as cubic boron nitride (CBN) tools, for high speed continuous machining.
970 citations
TL;DR: In this article, the authors focused on Inconel 718 and recent work and advances concerning machining of this material are presented, and some solutions to reduce the use of coolants are explored, and different coating techniques to enable a move towards dry machining are examined.
Abstract: The increasing attention to the environmental and health impacts of industry activities by governmental regulation and by the growing awareness in society is forcing manufacturers to reduce the use of lubricants. In the machining of aeronautical materials, classified as difficult-to-machine materials, the consumption of cooling lubricant during the machining operations is very important. The associated costs of coolant acquisition, use, disposal and washing the machined components are significant, up to four times the cost of consumable tooling used in the cutting operations. To reduce the costs of production and to make the processes environmentally safe, the goal of the aeronautical manufacturers is to move toward dry cutting by eliminating or minimising cutting fluids. This goal can be achieved by a clear understanding of the cutting fluid function in machining operations, in particular in high speed cutting, and by the development and the use of new materials for tools and coatings. High speed cutting is another important aspect of advanced manufacturing technology introduced to achieve high productivity and to save machining cost. The combination of high speed cutting and dry cutting for difficult-to-cut aerospace materials is the growing challenge to deal with the economic, environmental and health aspects of machining. In this paper, attention is focussed on Inconel 718 and recent work and advances concerning machining of this material are presented. In addition, some solutions to reduce the use of coolants are explored, and different coating techniques to enable a move towards dry machining are examined.
598 citations
TL;DR: In this article, the authors present a review of previous research on heat generation and heat dissipation in the orthogonal machining process and propose some modelling requirements for computer simulation of high speed machining processes.
Abstract: Determination of the maximum temperature and temperature distribution along the rake face of the cutting tool is of particular importance because of its controlling influence on tool life, as well as, the quality of the machined part. Numerous attempts have been made to approach the problem with different methods including experimental, analytical and numerical analysis. Although considerable research effort has been made on the thermal problem in metal cutting, there is hardly a consensus on the basics principles. The unique tribological contact phenomenon, which occur in metal cutting is highly localized and non-linear, and occurs at high temperatures, high pressures and high strains. This has made it extremely difficult to predict in a precise manner or even assess the performance of various models developed for modelling the machining process. Accurate and repeatable heat and temperature prediction remains challenging due to the complexity of the contact phenomena in the cutting process. In this paper, previous research on heat generation and heat dissipation in the orthogonal machining process is critically reviewed. In addition, temperature measurement techniques applied in metal cutting are briefly reviewed. The emphasis is on the comparability of test results, as well as, the relevance of temperature measurement method to high speed cutting. New temperature measurement results obtained by a thermal imaging camera in high speed cutting of high strength alloys are also presented. Finally, the latest work on estimation of heat generation, heat partition and temperature distribution in metal machining is reviewed. This includes an exploration of the different simplifying assumptions related to the geometry of the process components, material properties, boundary conditions and heat partition. The paper then proposes some modelling requirements for computer simulation of high speed machining processes.
541 citations
Cites methods from "Temperature and wear of cutting too..."
...employed this technique to study the effect of the cutting temperature on the tool wear in high speed turning of Inconel 718 and milling of Ti-6Al-6V-2Sn alloy [20]....
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TL;DR: In this article, the authors focused on the tool wear characteristics in the machining of nickel-based superalloys, and the state of the art in the fields of failure mechanism, monitoring and prediction, and control of tool wear are reviewed.
Abstract: Nickel-based superalloy is widely employed in aircraft engines and the hot end components of various types of gas turbines with its high strength, strong corrosion resistance and excellent thermal fatigue properties and thermal stability. However, nickel-based superalloy is one of the extremely difficult-to-cut materials. During the machining process, the interaction between the tool and the workpiece causes the severe plastic deformation in the local area of workpiece, and the intense friction at the tool–workpiece interface. The resulting cutting heat coupled with the serious work hardening leads to a series of flaws, such as excessive tool wear, frequent tool change, short tool life, low productivity, and large amount of power consumption etc., in which the excessive tool wear has become one of the main bottlenecks that constraints the machinability of nickel-based superalloys and its wide range of applications. In this article, attention is mainly focused on the tool wear characteristics in the machining of nickel-based superalloys, and the state of the art in the fields of failure mechanism, monitoring and prediction, and control of tool wear are reviewed. The survey of existing works has revealed several gaps in the aspects of tool self-organizing process based on the non-equilibrium thermodynamics, tool wear considering the tool nose radius, thermal diffusion layer in coated tools, tool life prediction based on the thermal–mechanical coupling, and industrial application of tool wear online monitoring devices. The review aims at providing an insight into the tool wear characteristics in the machining of nickel-based superalloys and shows the great potential for further investigations and innovation in the field of tool wear.
409 citations
References
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Book•
15 Mar 1960
TL;DR: In this paper, the authors describe typical cutting operations, including: Elastic Behaviour Plastic Behaviour Fracture Dynamometry Shear Strain in Cutting Shear Stress in Cutting Friction Wear and Tool Life Cutting Temperatures Cutting Fields Tool Materials Work Material Considerations Complex Tools Surface Integrity Chip Control Optimisation Modeling of Chip Formation Precision Engineering Unusual Applications of the Metal Cutting Process
Abstract: Table of Contents Preface Symbols Introduction Typical Cutting Operations Mechanics of Steady State Elastic Behaviour Plastic Behaviour Fracture Dynamometry Shear Strain in Cutting Shear Stress in Cutting Friction Wear and Tool Life Cutting Temperatures Cutting Fields Tool Materials Work Material Considerations Complex Tools Surface Integrity Chip Control Optimisation Modeling of Chip Formation Precision Engineering Unusual Applications of the Metal Cutting Process
2,229 citations
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TL;DR: The implementation of fundamental knowledge of high-speed machining into the manufacture of industrial products took a relatively long time as discussed by the authors, not only due to a cautious attitude of the industry, but also to the production facilities existing at the time when the first findings became available from research not meeting the requirements of high speed machining.
419 citations
TL;DR: In this article, a simple quantitative expression for abrasive wear rate is developed, and the abrasive data of a number of earlier investigators is analyzed in terms of this expression. But the results of this analysis are limited, since the average loose abrasive grain spends 90% of its time rolling and only 10% of the time abrading the sliding surfaces between which it is situated.
394 citations
TL;DR: In this paper, the authors report some new findings towards the goal of understanding the mechanics of chip formation when machining Titanium and other aerospace structural superalloys, which is difficult to machine except at low cutting speeds because of rapid tool wear.
386 citations
TL;DR: In this paper, the authors proposed an energy-based method to predict chip formation and cutting force for a single point tool of arbitrary geometry, using the predicted results together with an assumption made on the stress distribution on the tool face, the temperature distribution within chip and tool is obtained through a numerical analysis.
Abstract: Through the energy method proposed in the previous parts of this study, it is possible to predict chip formation and cutting force for a single point tool of arbitrary geometry. By using the predicted results together with an assumption made on the stress distribution on the tool face, the temperature distribution within chip and tool is obtained through a numerical analysis. A characteristic equation of crater wear of carbide tool is derived theoretically and verified experimentally. Computer simulation of crater wear development is then carried out by using the characteristic equation, and the predicted distributions of the stress and the temperature.
232 citations