Abstract
Inconel 718 is a Ni superalloy widely used in high responsibility components requiring excellent mechanical properties at high temperature and elevated corrosion resistance. Inconel 718 is a difficult to cut material due to the elevated temperature generated during cutting, its low thermal conductivity, and the strong abrasive tool wear during cutting process. Finishing operations should ensure surface integrity of the component commonly requiring the use of hard metal tools with sharp tool edges and moderate cutting speeds. Polycrystalline cubic boron nitride (PCBN) tools recently developed an enhanced toughness suitable for these final operations. This paper focuses on the study of PCBN tools performance in finishing turning of Inconel 718. Several inserts representative of different manufacturers were tested and compared to a reference carbide tool. The evolution of tool wear, surface roughness, and cutting forces was analyzed and discussed. PCBN tools demonstrated their suitability for finishing operations, presenting reasonable removal rates and surface quality.
Highlights
Nickel-based superalloys with excellent mechanical properties at high temperature and corrosion resistance find a wide range of applications such as aircraft engines power-generation turbines, nuclear power generation, and chemical processes involving aggressive environments [1,2]
This paper focuses on finishing turning with coolant of Inconel 718 with different Polycrystalline cubic boron nitride (PCBN) tools with low content of cubic boron nitride (CBN)
Finishing turning of Inconel 718 has been analyzed in this paper, testing commercial PCBN tools with low CBN content from different manufacturers: CBN 170 (Seco), KB5625 (Kennametal), MB8025 (Mitsubishi), and 7015 (Sandvik)
Summary
Nickel-based superalloys with excellent mechanical properties at high temperature and corrosion resistance find a wide range of applications such as aircraft engines power-generation turbines, nuclear power generation, and chemical processes involving aggressive environments [1,2]. Surface integrity and tool wear are challenges when machining these difficult to cut materials due to strong work hardening, presence of hard carbides, and low thermal conductivity leading to high temperatures during machining [3,4,5]. Proper tool selection and definition of cutting parameters are critical in order to ensure productivity in machining processes of Ni alloys. Geometry, and coating; cooling strategy; and cutting parameters (cutting speed and feed) strongly determine tool wear evolution and surface integrity [6,7]. Extreme conditions during cutting require the use of advanced tool materials such as cemented tungsten carbides, ceramics, and cubic boron nitride (CBN) being the main cutting material families used in rough machining of Ni superalloys [8].
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