An Approach for Reducing Cutting Energy Consumption with Ultra-High Speed Machining of Super Alloy Inconel 718

Abstract

High energy efficient machining is beneficial for sustainable manufacture which is an important target pursued by workshops. The paper aims to prove the feasibility for reducing cutting energy consumption with ultra-high speed machining (UHSM) of super alloy Inconel 718. Firstly, orthogonal cutting experiments of Inconel 718 are performed with a wide cutting speed range. Through analyses of chip micrographs, it is found that plastic deformation accompanied with ductile fracture contributes to serrated chip formation, while fragmented chips are produced through brittle fracture. The results demonstrate that brittle regime machining can be realized for Inconel 718 with ultra-high cutting speeds. Secondly, considering varied deformation behavior for chips with different morphologies, specific cutting energy models for HSM under varied cutting parameters are developed and verified. Then the influences of cutting speed and uncut chip thickness on cutting energy consumption during HSM are revealed. The research results demonstrate the practicability for reducing cutting energy consumption with brittle regime machining of Inconel 718. At last, the relationship between AE signals and cutting energy consumption is explored, and it proves that AE signals are applicable in monitoring cutting energy consumption. The research can provide guidance for energy saving through optimizing cutting parameters.