Inconel 718, known for its excellent high-temperature mechanical properties, is widely used in crucial aircraft engine components. Due to its poor machinability, ceramic tools are often employed to enhance cutting efficiency, but they suffer from severe wear, which deteriorates surface integrity and shortens component service life. This limits their application in finishing processes and key structural parts. This study conducted machining experiments on Inconel 718 using ceramic and cemented carbide tools to analyze the effects of different tool wear levels on the workpiece surface integrity. The relationship between surface integrity and fatigue life was further investigated. Based on the observation that ceramic tool machining led to the formation of a surface metamorphic layer, a machining strategy was proposed to improve fatigue life by removing the affected layer (RAL) using cemented carbide tools. The effectiveness of this strategy was experimentally compared with laser shock peening (LSP) and ultrasonic cavitation peening (USCP). The results showed that machining with ceramic tools produced a surface metamorphic layer, increased surface roughness and microhardness, and introduced tensile residual stress. These adverse factors intensified with increasing tool wear, ultimately reducing the fatigue life to ∼0.41 times that of components machined by cemented carbide tools. Using RAL, the fatigue life was improved by 2.36, 1.75, and 2.78 times compared to ceramic tool machining only, LSP, and USCP, respectively. The optimal removal depth was determined to be 120 μm. This strategy effectively expanded the applicability of ceramic tools in machining critical aerospace components.
LiangXLiuZWangB.State-of-the-art of surface integrity induced by tool wear effects in machining process of titanium and nickel alloys: a review. Measurement2019; 132: 150–181.
2.
YinQLiuZWangB, et al. Recent progress of machinability and surface integrity for mechanical machining Inconel 718: a review. Int J Adv Manuf Technol2020; 109: 215–245.
3.
KurtAYalcinBYilmazN.The cutting tool stresses in finish turning of hardened steel with mixed ceramic tool. Int J Adv Manuf Technol2015; 80: 315–325.
4.
GrgurasDKernMPusavecF. Suitability of the full body ceramic end milling tools for high speed machining of nickel based alloy Inconel 718. In: 8th CIRP Conference on High Performance Cutting (HPC 2018) 2018, 2018, vol. 77, pp.630–633.
5.
YuWMingWAnQ, et al. Wear behavior of SiAlON ceramic tool and its effects during high-speed cutting. Ceram Int2023; 49: 26694–26706.
6.
WangD.Research on surface integrity and its influencing factors in the high-speed cutting of typical aluminum/titanium/nickel alloys: a review. Int J Adv Manuf Technol2023; 127: 4915–4942.
7.
SarikayaMGuptaMKTomazI, et al. A state-of-the-art review on tool wear and surface integrity characteristics in machining of superalloys. CIRP J Manuf Sci Technol2021; 35: 624–658.
8.
WangBLiuZ.Influences of tool structure, tool material and tool wear on machined surface integrity during turning and milling of titanium and nickel alloys: a review. Int J Adv Manuf Technol2018; 98: 1925–1975.
9.
SainiSAhujaISSharmaVS.Modelling the effects of cutting parameters on residual stresses in hard turning of AISI H11 tool steel. Int J Adv Manuf Technol2013; 65: 667–678.
10.
ToubhansBFromentinGVipreyF, et al. Machinability of Inconel 718 during turning: cutting force model considering tool wear, influence on surface integrity. J Mater Process Technol2020; 285: 22–32.
11.
XuDDLiuYDingL, et al. Experimental and numerical investigation of Inconel 718 machining with worn tools. J Manuf Process2022; 77: 163–173.
12.
TanLYaoCZhangD, et al. Effects of tool wear on machined surface integrity during milling of Inconel 718. Int J Adv Manuf Technol2021; 116: 2497–2509.
13.
OsmondLCurtisDSlatterT.Chip formation and wear mechanisms of SiAlON and whisker-reinforced ceramics when turning Inconel 718. Wear2021; 486–487: 204128.
14.
MaZXuXWHuangXH, et al. Cutting performance and tool wear of SiAlON and TiC-whisker-reinforced Si3N4 ceramic tools in side milling Inconel 718. Ceram Int2022; 48: 3096–3108.
15.
OliveiraARFda SilvaLRRBaldinV, et al. Effect of tool wear on the surface integrity of Inconel 718 in face milling with cemented carbide tools. Wear2021; 476: 203752.
16.
HolmbergJWretlandABerglundJ, et al. Selection of milling strategy based on surface integrity investigations of highly deformed Alloy 718 after ceramic and cemented carbide milling. J Manuf Process2020; 58: 193–207.
17.
RazakNHChenZWPasangT.Modes of tool deterioration during milling of 718Plus superalloy using cemented tungsten carbide tools. Wear2014; 316: 92–100.
18.
ZhaoJLiuZShenQ, et al. Investigation of cutting temperature during turning Inconel 718 with (Ti,Al)N PVD coated cemented carbide tools. Materials2018; 11(8): 1281.
19.
TuLLinLLiuC, et al. Tool wear characteristics analysis of cBN cutting tools in high-speed turning of Inconel 718. Ceram Int2023; 49: 635–658.
20.
MadariagaAGarayAEsnaolaJA, et al. Effect of surface integrity generated by machining on isothermal low cycle fatigue performance of Inconel 718. Eng Fail Anal2022; 137: 106422.
21.
RenXLiuZLiangX, et al. Effects of machined surface integrity on high-temperature low-cycle fatigue life and process parameters optimization of turning superalloy Inconel 718. Materials2021; 14(9): 2428.
22.
Infante-GarcíaDDíaz-ÁlvarezABeldaR, et al. Influence of machining parameters on fretting fatigue life of Inconel 718. Int J Fatigue2022; 162: 106963.
23.
ChilderhouseTM’SaoubiRFrancaL, et al. The influence of machining induced surface integrity and residual stress on the fatigue performance of Ti-6Al-4V following polycrystalline diamond and coated cemented carbide milling. Int J Fatigue2022; 163: 107054.
24.
RenXLiuZ.A simulation model for predicting surface integrity coupled thermal-mechanical effect in turning of Inconel 718 super alloy. Int J Adv Manuf Technol2019; 100: 1825–1837.
25.
WangXHuangCZouB, et al. Experimental study of surface integrity and fatigue life in the face milling of Inconel 718. Front Mech Eng2018; 13: 243–250.
26.
JavadiHJomaaWSongmeneV, et al. Inconel 718 superalloy controlled surface integrity for fatigue applications produced by precision turning. Int J Precis Eng Manuf2019; 20: 1297–1310.
27.
GalatoloRFanteriaD.Influence of turning parameters on the high-temperature fatigue performance of Inconel 718 superalloy. Fatigue Fract Eng Mater Struct2017; 40: 2019–2031.
28.
HolmbergJWretlandAHammersbergP, et al. Surface integrity investigations for prediction of fatigue properties after machining of Alloy 718. Int J Fatigue2021; 144: 106059.
29.
KattouraMMannavaSRQianD, et al. Effect of laser shock peening on residual stress, microstructure and fatigue behavior of ATI 718Plus alloy. Int J Fatigue2017; 102: 121–134.
30.
KattouraMMannavaSRQianD, et al. Effect of laser shock peening on elevated temperature residual stress, microstructure and fatigue behavior of ATI 718Plus alloy. Int J Fatigue2017; 104: 366–378.
31.
YinXLiXLiuY, et al. Surface integrity and fatigue life of Inconel 718 by ultrasonic peening milling. J Mater Res Technol2023; 22: 1392–1409.
32.
YinXLiuYZhaoS, et al. Tool wear and its effect on the surface integrity and fatigue behavior in high-speed ultrasonic peening milling of Inconel 718. Tribol Int2023; 178(Pt A): 108070.
33.
CuiPLiuZZhaoJ, et al. Correlation between surface integrity and low cycle fatigue life of machined Inconel 718. Metals2024; 14(2): 178.
34.
HuaYLiuZWangB, et al. Surface modification through combination of finish turning with low plasticity burnishing and its effect on fatigue performance for Inconel 718. Surf Coat Technol2019; 375: 508–517.
35.
ShengJZhangHHuX, et al. Influence of laser peening on the high-temperature fatigue life and fracture of Inconel 718 nickel-based alloy. Theor Appl Fract Mech2020; 109: 102757.
36.
ShengJLiuHLinY, et al. Micromechanism of high-temperature fatigue properties of Inconel 718 nickel-based alloy treated by laser peening. J Laser Micro Nanoeng2022; 17: 58–68.
37.
WuDYaoCZhangD.Surface characterization and fatigue evaluation in GH4169 superalloy: comparing results after finish turning; shot peening and surface polishing treatments. Int J Fatigue2018; 113: 222–235.
MaJGaoYJiaZ, et al. Influence of spindle speed on tool wear in high-speed milling of Inconel 718 curved surface parts. Proc Inst Mech Eng B J Eng Manuf2018; 232: 1331–1341.
40.
OsmondLCookICurtisD, et al. Tool life and wear mechanisms of CVD coated and uncoated SiAlON ceramic milling inserts when machining aged Inconel 718. Proc Inst Mech Eng B J Eng Manuf2024; 238: 1069–1083.
41.
PanLWuZRFangL, et al. Investigation of surface damage and roughness for nickel-based superalloy GH4169 under hard turning processing. Proc Inst Mech Eng B J Eng Manuf2020; 234: 679–691.
42.
MaJJiaZHeG, et al. Influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface. Proc Inst Mech Eng B J Eng Manuf2019; 233: 18–30.
43.
LiDZhangTZhaoN, et al. Investigation on the thermal-mechanical coupling effect on wear mechanism of high-speed cutting nickel-based superalloy GH4169 with cermet cutting tools. Proc Inst Mech Eng B J Eng Manuf2025; 239: 901–914.
44.
YaoGLiuZSongQ, et al. Numerical prediction and experimental investigation of residual stresses in sequential milling of GH4169 considering initial stress effect. Int J Adv Manuf Technol2022; 119: 7215–7228.
45.
CangXShuLLiP, et al. Establishment and experimental verification of a three-dimensional finite element model for residual stress in surface processing of Inconel 718 alloy by laser cladding. Mater Today Commun2023; 37: 107088.
46.
de Paula OliveiraGFonsecaMCAraujoAC. Analysis of residual stress and cutting force in end milling of Inconel 718 using conventional flood cooling and minimum quantity lubrication. Int J Adv Manuf Technol2017; 92: 3265–3272.
47.
CuiC-HZhuZ-QChenZ-T, et al. Surface integrity and fatigue life of GH4169 by combined process of milling, grinding, and polishing. Proc Inst Mech Eng B J Eng Manuf2024; 238: 1914–1923.
