Abstract
It is essential for superalloys (e.g., Inconel 718) to obtain an anticipated surface integrity after machining, especially for safety critical areas (e.g., aerospace). As one of the main characteristics for cutting tools, the rake angle has been recognized as a key factor that can significantly influence the machining process. Although there are large research interests and outcomes in the machining of nickel-based superalloys, most of them focus on the surface integrity and macroscale temperature observation, whereas the temperature distribution in the tool rake face is not clear. Thus, it is necessary to investigate the basic role of rake angles and the tool–workpiece interaction mechanism to determine the machining condition variations and surface integrity. In the present study, both experimental and numerical methods are employed to explore the cutting force, thermal distribution, and shear angles during the process and the metallurgy characteristics of the subsurface after machining, as well as the mechanical properties. The research has emphasized the importance of rake angles on both the cutting process and machined surface integrity, and has revealed the microscale temperature distribution in the tool rake face, which is believed to have a close relationship with the tool crater wear. In addition, it is clearly presented that the surface generated with positive rake angle tools generates the minimum subsurface deformation and less strain hardening on the workpiece.
Highlights
The performance of an aeroengine is tightly related to the innovation design and high strength materials used in the engine [1,2,3]
The results have clearly emphasized that the rake angle incan significantly decrease the cutting force during the machining of Inconel 718, which creasing can significantly decrease the cutting force during the machining of Inconel 718, is consistent with the former observation, and that the built model could appropriately which is consistent with the former observation, and that the built model could approprireplicate the cutting process for further analysis
The rake angles used for cutting tools significantly influence the cutting process, including, but not limited to, the cutting force, temperature, chips formation, and the surface integrity, which is one of the main concerns for manufacturers
Summary
The performance of an aeroengine is tightly related to the innovation design and high strength materials used in the engine [1,2,3]. It has been an attractive topic, since these kinds of materials have been developed and introduced into industries, and much research has been carried out to study the machinability of superalloys. The cutting process with different tool materials (e.g., CBN, solid carbide, coated or uncoated etc.) has been studied by exploring both the tool tip wear and reaction between workpiece and tool [7,8]. Researchers have carried out many investigations on the machinability of aeroengine alloys (Inconel 718) because of their dominance of a typical engine [9]. In the cutting process, a large amount of heat is generated, which damages the machine surface integrity and accelerates the tool wearing, the coolant method has been referred in order to study the cutting process and influence on tool life [10]
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