Abstract
Super-alloys encompass great challenges in machinability. One such alloy of much interest in applications is Inconel 718. Its increased hardness, low thermal diffusivity and high temperature strength make it desirable for applications, at the same time rendering its machining a demanding task. Extensive studies have been performed on machinability of Inconel 718, from the turning process stand-point. However, there is found to be a comparative dearth of work on the milling process. Taking into account the versatility of end-milling within the family of milling processes and the research gap, we found that a parametric optimization (aimed at minimum machining forces) of end-milling would be a meaningful effort. An experiment was conducted to study conditions that would help us achieve the same. In our further quest for optimization, chip morphology studies using SEM occupied a special place. Bearing in mind immense prediction capabilities of computer simulations based on FEA available today, we attempted process replication of the experimental work. The significant cutting forces were chosen as the benchmark factor for this purpose and proper attention was given to validation of the FEM created. Such FEM holds promise of being resourceful to drive up efficiency, with consequent spill-over to the production line.
Highlights
Inconel 718 is a Nickel-Chromium-Molybdenum alloy designed to resist a wide range of severely corrosive environments, especially pitting and crevice corrosion
Force (Fx) is detrimental from the standpoint of tool life as well as process stability, we conclude that the regime of high Feed Rates, where such behavior is prone to occur, is not recommendable for Inconel 718 end-milling
The only exception is some midpoints in the Cutting Speed range and the high Feed Rate plot (Fig. 14) where the reverse trend is observed for Cutting Force, Fx
Summary
Inconel 718 is a Nickel-Chromium-Molybdenum alloy designed to resist a wide range of severely corrosive environments, especially pitting and crevice corrosion. This Nickel-Steel alloy displays exceptionally high Yield, Tensile, and Creep-Rupture properties at high temperatures. Nickel-base super-alloys like Inconel are generally known to be one of the most difficult- to-machine materials because of their high hardness, strength at elevated temperatures, and low thermal diffusivity. Inconel is a difficult metal to shape, using traditional cold forming techniques, due to rapid work-hardening. Research work on machining modeling has a focus on predictive ability and is most concentrated in the turning process of metal removal. Important factors of machining such as Cutting Forces, Temperatures, Chip Configuration, Strains and Stresses, if estimated
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