Abstract
This paper focuses on an analysis of tool wear and optimum machining parameter in the induction assisted milling of Inconel 718 using high heat coated carbide and uncoated carbide tools. Thermally assisted machining is an effective machining method for difficult-to-cut materials such as nickel-based superalloy, titanium alloy, etc. Thermally assisted machining is a method of softening the workpiece by preheating using a heat source, such as a laser, plasma or induction heating. Induction assisted milling is a type of thermally assisted machining; induction preheating uses eddy-currents and magnetic force. Induction assisted milling has the advantages of being eco-friendly and economical. Additionally, the preheating temperature can be easily controlled. In this study, the Taguchi method is used to obtain the major parameters for the analysis of cutting force, surface roughness and tool wear of coated and uncoated tools under various machining conditions. Before machining experiments, a finite element analysis is performed to select the effective depth of the cut. The S/N ratio and ANOVA of the cutting force, surface roughness and tool wear are analyzed, and the response optimization method is used to suggest the optimal machining parameters.
Highlights
The production of difficult-to-cut materials has increased in various engineering industries
According to the heat source type, machining can be classified into categories of induction assisted milling (IAM), laser-assisted milling (LAM), electrochemical assisted machining (ECAM) and plasma assisted milling (PAM)
The experimental results for cutting force, surface roughness, tool wear and the signal to noise (S/N) ratio are shown in Tables 5–7, for the coated tool and the uncoated tool
Summary
The production of difficult-to-cut materials has increased in various engineering industries. There are difficult-to-cut materials that have properties such as a high corrosion resistance, thermal resistance, good specific strength, etc. Nickel-based super-alloys are metallic materials with a high temperature strength, toughness, and resistance to deterioration in corrosive or oxidizing environments [3,4,5]. Assisted machining uses heat sources to heat the workpiece and soften it. These machining methods have some advantages, such as a decrease in the cutting force and an improvement of surface roughness and energy saving compared to the conventional machining method [6,7,8,9,10]
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