Abstract
Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces, and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness, and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration, and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration, and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated. Also, in this study, the statistical validity of the experimental values was tested with the help of second-order equations and analyses of variance (ANOVA). R2 values obtained as 99.14%, 99.76%, and 97.98% for vibration, surface roughness, and feed force values were modeled statistically with the help of second-order equations, respectively.
Highlights
Inconel 718 is a nickel-based super alloy with high mechanical properties such as high temperature, corrosion resistance and oxidation even at very high temperatures [1,2,3,4,5,6]
The graphs of the feed forces measured during the milling of the Inconel 718 super alloy with cryogenically treated (CT) and CU cutting tools are given in Fig. 3 and Fig. 4
In the literature, feed rate that affect feed forces was discussed by many authors [9, 20, 24]
Summary
Inconel 718 is a nickel-based super alloy with high mechanical properties such as high temperature, corrosion resistance and oxidation even at very high temperatures [1,2,3,4,5,6]. Inconel 718 is classified as "materials difficult to machine" due to high cutting temperature and high cutting force created by its characteristic properties such as low thermal conductivity, hardness, tendency to react with the cutting tool material, presence of abrasive carbide particles and work hardening For this reason, it is of great importance to control and select the suitable machining parameters and conditions such as cutting parameters, cutting tool geometry and coating material selection, coolant while these difficult-to-machine workpieces are machined. In order to solve the problems encountered during the machining of these materials, the application comes to the forefront especially because of the features that the cryogenic process gives the cutting tool In this experimental study, the effects of especially CT and CU cutting tools on feed forces, surface roughness, vibration, cutting tool wear, hardness and abrasive wear that occur as a result of milling Inconel 718 workpiece were investigated
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