Effect of Increasing Spindle Speed at a Constant Chip Load on Cutting Force Behaviour of Hastelloy X

Nor Aznan Mohd Nor,‪Armansyah Ginting,Mohd Khairol Anuar Mohd Ariffin,Bt Hang Tuah Baharudin,Zulkiflle Leman,Jaharah A Ghani,‪Napsiah Ismail

doi:10.15282/ijame.18.2.2021.03.0659

Nor Aznan Mohd Nor, ‪Armansyah Ginting + Show 5 more

Open Access

https://doi.org/10.15282/ijame.18.2.2021.03.0659

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Abstract

Cutting force is vital in machining nickel-based superalloys due to their excellent mechanical properties, thus creating difficulty in cutting. In the current scenario of metal machining, milling processes require high spindle speed and low chip load, which result in a low cutting force. However, low chip load not only result in low cutting force but also result in a low material removal rate (MRR). It is contrary to the ultimate high-speed machining (HSM) goal, which is to improve productivity and cost-effectiveness. Therefore, the emergence of an approach for achieving simultaneous low cutting force and high MRR is crucial. This paper presents the effect of increasing spindle speed at a constant chip load on the cutting force of Hastelloy X during half-immersion up-milling and half-immersion down-milling. In both half-immersions, the simulation results and experimental results are in good agreement. The percentage contribution of feed force, normal force and axial force to the resultant force can be arranged descendingly from high to low as axial force > normal force > axial force. Moreover, feed force, normal force, axial force and resultant force have a U-shaped behaviour. The spindle speed of 24,100 rpm and a chip load of 0.019 mm/tooth were found to achieve both low cutting force and high MRR.

Highlights

Cutting force issues are frequently encountered in the aerospace manufacturing industry due to nickel-based superalloys that tend to be more difficult to machine compared to other traditional materials
Since all runs in this research only considered the value of cutting force component per flute, the values of feed force, the normal force and the axial force in Figure 1 were recorded at a cutting time of 0.00113 s due to the cutting length was set at 0.013 mm
By observing the results of the cutting force components and resultant force in Figure 2 to Figure 5, the findings indicated that the axial forces dominated a total resultant force with an estimation of 60% during half-immersion up-milling and 51% during half-immersion down-milling

Summary

Introduction

Cutting force issues are frequently encountered in the aerospace manufacturing industry due to nickel-based superalloys that tend to be more difficult to machine compared to other traditional materials. Hastelloy X or Inconel HX is one of the most widely used nickel-based superalloys for aerospace components, such as structure [1] and gas turbine engines for the combustion zone components [2,3,4,5]. Cutting force is commonly divided into three components, which are feed force, normal force and axial force [8]. These cutting force components can be accurately measured by strain gauge sensors [8] or piezoelectric sensors [8, 10] embedded in the dynamometer. The cutting force can be predicted via Finite Element Method (FEM) techniques by analysing chip formation in metal machining [11]

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Conclusion