Comparison of Flank Super Abrasive Machining vs. Flank Milling on Inconel® 718 Surfaces.

Haizea González,L López De Lacalle,Octavio Pereira,Asier Fernández-Valdivielso,Amaia Calleja

doi:10.3390/ma11091638

Abstract

Thermoresistant superalloys present many challenges in terms of machinability, which leads to finding new alternatives to conventional manufacturing processes. In order to face this issue, super abrasive machining (SAM) is presented as a solution due to the fact that it combines the advantages of the use of grinding tools with milling feed rates. This technique is commonly used for finishing operations. Nevertheless, this work analyses the feasibility of this technique for roughing operations. In order to verify the adequacy of this new technique as an alternative to conventional process for roughing operations, five slots were performed in Inconel® 718 using flank SAM and flank milling. The results showed that flank SAM implies a suitable and controllable process to improve the manufacture of high added value components made by nickel-based superalloys in terms of roughness, microhardness, white layer, and residual stresses.

Highlights

Thermoresistant superalloys, such as titanium- and nickel-based alloys, are an actual challenge for manufacturing technologies
With the aim of analysing the adequacy of flank super abrasive machining (SAM) compared to flank milling in terms of surface integrity applied to thermo-resistant super alloys, a serial of experiments were designed
With the aim of analysing the feasibility of this manufacturing technique compared to the conventional one, roughness, microstructure and white layer, residual stresses, and microhardness were measured after manufacturing

Summary

Introduction

Thermoresistant superalloys, such as titanium- and nickel-based alloys, are an actual challenge for manufacturing technologies These alloys are widely used for many applications that require stability of material properties working under extreme conditions and temperatures up to 400 ◦ C and 600 ◦ C, respectively [1]. Inconel® 718, has multiple applications as a consequence of its mechanical and physical properties, it is spreading to industries such as petrochemical plants, marine equipment, food processing equipment, and nuclear reactors [4]. These alloys are known as difficult-to-cut materials, implying premature tool wear and high cutting forces [5,6]. The challenge lies in the low machinability combined with difficult geometries and finishing requirements that leads to optimizing traditional manufacturing processes, improving cutting strategies, new tools design [7], and cooling techniques on milling Inconel® 718 [8,9]

Methods

Results

Conclusion