The Effects of Cutting Conditions on Surface Integrity in Machining Waspaloy

Abstract

Machining of advanced aerospace materials have grown in the recent years although the difficult-to-machine characteristics of alloys like titanium or nickel based alloys cause higher cutting forces, rapid tool wear, and more heat generation. Therefore, machining with the use of cooling lubricants is usually carried out. To reduce the production costs and to make the processes environmentally safe, the goal is to move toward dry cutting by eliminating cutting fluids. This objective can be achieved by using coated tool, by increasing cutting speed and by improving the product performance in term of surface integrity and product quality. The paper addresses the effects of cutting speed and feed on the surface integrity during dry machining of Waspaloy using coated tools. In particular, the influence of the cutting conditions on mechanical power consumption, the tool wear and some important indicator of the surface integrity (surface roughness, affected layer, microhardness, grain size and microstructural alteration) were investigated. Results show that cutting conditions have a significant effect on the parameters related to the surface integrity of the product affecting its overall performance.