Abstract
Inconel 718 is widely used in various high end industries such as aerospace, nuclear plant, petrochemical plants etc. Inconel 718 is used for these applications due to unique mechanical properties such as high mechanical strength at elevated temperatures, high resistance to corrosion, and high strength to weight ratio. The unique properties of Inconel 718 made it difficult to be machined due to rapid work hardening and high cutting temperature. In addition, chatter vibration further increases the difficulty in machining of Inconel 718. In this paper, an experimental study on the effects of tool edge radius to the chatter behaviour was investigated. The dynamic responses of the milling process were recorded and analysed in both time domain and frequency domain. The results showed the variable helix and pitch end mill tool with larger tool edge radius able to mitigate chatter vibration at lower cutting speeds. Variable helix and pitch end mill with specific tool edge radius able to mitigate chatter vibration under the same cutting parameters. Experiments shows proper selection of tool edge radius improves the stability of end milling machining process.
Highlights
Inconel 718 is one of the Nickel based super alloys that are widely used in the various industries such as aerospace, nuclear, petrochemical plants, food processing equipment and etc [1,2,3]
The results showed the variable helix and pitch end mill tool with larger tool edge radius able to mitigate chatter vibration at lower cutting speeds
Experiments shows proper selection of tool edge radius improves the stability of end milling machining process
Summary
Inconel 718 is one of the Nickel based super alloys that are widely used in the various industries such as aerospace, nuclear, petrochemical plants, food processing equipment and etc [1,2,3]. The thermal load in the cutting tool edge should be able to reduce by spreading across the tool edge radius, potentially reduce the cutting temperature This is especially important when machining a high heat resistance material such as Inconel 718. Variable pitch and helix cutting tools are able to mitigate the chatter vibration, and with the combination of tool edge radius, the cutting temperature reduces compare to the sharp cutting edge. The research articles related to the experimental investigations with variable pitch and variable helix angle milling cutters with tool edge radius is very limited in the literature especially in the end milling process of Inconel 718. The variable pitch and helix end mill cutters are employed to study the effect of tool edge radius to the chatter vibration in the milling process of Inconel 718. Dynamics responses were recorded and analyzed during the milling process in the time domain and frequency domain to evaluate the chatter characteristic
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