Tool wear/life evaluation when finish turning Inconel 718 using PCBN tooling

Research output: Contribution to journalArticlepeer-review

Authors

  • Sarmad Khan
  • C. Sage
  • P. Harden
  • M. Fleming
  • A. White
  • R. M'Saoubi

Abstract

Following a brief review of related literature, the paper outlines experimental results following finish turning of Inconel 718 using low concentration PCBN inserts. Testing utilised a modified L36 Taguchi fractional factorial orthogonal array which evaluated the effects of tool insert shape/geometry (round, C-type), tool edge preparation (extra honed, chamfered & honed), fluid pressure (10, 100bar), tool coating (uncoated, TiAlN+TiN), cutting speed (150, 300, 450m/min) and feed rate (0.05, 0.10, 0.20mm/rev) at a constant depth of cut of 0.2mm. At the lowest cutting speed (150m/min), average tool life using the round insert was approximately 5 times longer in comparison to the C-type tool, with severe grooving and built up edge (BUE) formation observed on wear scar micrographs in all experiments with the latter. As cutting speed was increased to 300m/min, the presence of grooving and BUE diminished, leading to comparable performance between the C-type and round tools. When turning at 450m/min however, several instances of catastrophic insert fracture occurred and tool life did not exceed 3.5mins, irrespective of the other parameters/conditions used. Adhesion of workpiece material on tool cutting edges was prevalent over the range of parameters tested with abrasion typically the primary mechanism causing insert wear.

Details

Original languageEnglish
Pages (from-to)283-288
Number of pages6
JournalProcedia CIRP
Volume1
Issue number1
Publication statusPublished - 1 Jan 2012