Direct aged Inconel 718 superalloy is used in manufacturing critical cross-sections of aero-engine components. It is a hard-to-machine material, especially in dry conditions. To perform successful machining operations for this alloy, cutting tools with high hot hardness and chemical stability are required. The present study investigates the tool wear and chip formation during dry finish turning of direct aged Inconel 718 superalloy (51–53 HRC) using different ceramic tools. Pure alumina with added ZrO2 and alumina matrix reinforced with silicon carbide whiskers tools were used at cutting speeds of 150 and 250 m/min. A scanning electron microscope and energy dispersing spectroscopy were utilized to study the tool wear mechanisms. Structural and phase transformations during cutting on the tool–chip interface at the higher cutting speed were analyzed with X-ray photoelectron spectroscopy. Chip-undersides and cross-sections were studied with scanning electron microscope to investigate the chip formation mechanism. Results reveal that pure alumina with added ZrO2 can be an adequate choice for machining direct aged Inconel 718 because of its higher abrasive wear resistance and the formation of a sapphire protective tribo-layer at the tool–chip interface under severe cutting conditions. Chipping and notching of the cutting edge was found to decrease with the rise of the cutting speed for this tool material. As confirmed by X-ray photoelectron spectroscopy, alumina reinforced with silicon carbide whiskers tool was found to have a lower performance due the chemical degradation of the whiskers, especially at the higher cutting speed (250 m/min).
LeeHTHouWH. Development of fine-grained structure and the mechanical properties of nickel-based Superalloy 718. Mater Sci Eng A2012; 555: 13–20.
2.
FaymanYC. Microstructural characterization and elemental partitioning in a direct-aged superalloy (DA718). Mater Sci Eng1987; 92: 159–171.
3.
ArrazolaPJKortabarriaAMadariagaAet al.On the machining induced residual stresses in IN718 nickel-based alloy: experiments and predictions with finite element simulation. Simul Model Pract Theory2014; 41: 87–103.
4.
KuoCMYangYTBorHYet al.Aging effects on the microstructure and creep behavior of Inconel 718 superalloy. Mater Sci Eng A2009; 510–511: 289–294.
5.
TexierDCormierJVillechaisePet al.Crack initiation sensitivity of wrought direct aged alloy 718 in the very high cycle fatigue regime: the role of non-metallic inclusions. Mater Sci Eng A2016; 678: 122–136.
6.
ChoudhuryIAEl-BaradieMA. Machinability of nickel-base super alloys: a general review. J Mater Process Technol1998; 77: 278–284.
7.
RichardsNAspinwallD. Use of ceramic tools for machining nickel based alloys. Int J Mach Tools Manuf1989; 29: 575–588.
8.
DudzinskiDDevillezAMoufkiAet al.A review of developments towards dry and high speed machining of Inconel 718 alloy. Int J Mach Tools Manuf2004; 44: 439–456.
9.
LiWGuoYBBarkeyMEet al.Effect tool wear during end milling on the surface integrity and fatigue life of Inconel 718. Proc CIRP2014; 14: 546–551.
10.
EzugwuEOWangZMMachadoAR. The machinability of nickel-based alloys: a review. J Mater Process Technol1999; 86: 1–16.
11.
BrandtGGerendasAMikusM. Wear mechanisms of ceramic cutting tools when machining ferrous and non-ferrous alloys. J Eur Ceram Soc1990; 6: 273–290.
12.
ObikawaTYamaguchiM. Suppression of notch wear of a whisker reinforced ceramic tool in air-jet-assisted high-speed machining of Inconel 718. Precis Eng2015; 39: 143–151.
13.
ThakurDGRamamoorthyBVijayaraghavanL. Effect of cutting parameters on the degree of work hardening and tool life during high-speed machining of Inconel 718. Int J Adv Manuf Technol2012; 59: 483–489.
14.
KhidhirBAMohamedB. Study of cutting speed on surface roughness and chip formation when machining nickel-based alloy. J Mech Sci Technol2010; 24: 1053–1059.
15.
YoonHSKimESKimMSet al.Towards greener machine tools – a review on energy saving strategies and technologies. Renewable Sustain Energy Rev2015; 48: 870–891.
16.
DevillezASchneiderFDominiakSet al.Cutting forces and wear in dry machining of Inconel 718 with coated carbide tools. Wear2007; 262: 931–942.
17.
CourbonCKramarDKrajnikPet al.Investigation of machining performance in high-pressure jet assisted turning of Inconel 718: an experimental study. Int J Mach Tools Manuf2009; 49: 1114–1125.
18.
OjmertzKMCSkarsonHBO. Wear on Sic-whiskers reinforced ceramic inserts when cutting inconel with waterjet assistance. Tribol Trans1999; 42: 471–478.
19.
OkaforCJasraPM. Effects of cooling strategies and tool coatings on cutting forces and tooth frequency in high-speed down-milling of Inconel-718 using helical bull-nose solid carbide end mills. Int J Adv Manuf Technol2018; 97: 230–231.
20.
SunSBrandtMDarguschMS. Thermally enhanced machining of hard-to-machine materials – a review. Int J Mach Tools Manuf2010; 50: 663–680.
21.
DevillezACozGLDominiakSet al.Dry machining of Inconel 718, workpiece surface integrity. J Mater Process Technol2011; 211: 1590–1598.
22.
LimaFFSalesWFCostabESet al.Wear of ceramic tools when machining Inconel 751 using argon and oxygen as lubri-cooling atmospheres. Ceram Int2017; 43: 677–685.
23.
SemiatinSLRaoSB. Shear localization during metal cutting. Mater Sci Eng1983; 61: 185–192.
24.
MolinariAMusquarCSutterG. Adiabatic shear banding in high speed machining of Ti–6Al–4 V: experiments and modeling. Int J Plast2002; 18: 443–459.
25.
SutterG. Chip geometries during high-speed machining for orthogonal cutting condition. Int J Mach Tool Manuf2005; 45: 719–726.
26.
ShawMCVyasA. Chip formation in the machining of hardened steel. CIRP Ann Manuf Technol1993; 42: 29–33.
27.
ElbestawiMASrivastavaAKEl-WardanyTI. A model for chip formation during the machining of hardened steel. CIRP Ann Manuf Technol1996; 45: 71–76.
28.
WangBLiuZ. Serrated chip formation mechanism based on mixed mode of ductile fracture and adiabatic shear. Proc IMechE, Part B: J Engineering Manufacture2014; 228: 181–190.
29.
EzugwuEOBonneyJYamaneY. An overview of the machinability of aeroengine alloys. J Mater Process Technol2003; 134: 233–253.
30.
BushlyaVZhouJStåhlJE. Effect of cutting conditions on machinability of superalloy Inconel 718 during high speed turning with coated and uncoated PCBN tools. Proc CIRP2012; 3: 370–375.
31.
SooSLKhanSAAspinwallDKet al.High speed turning of Inconel 718 using PVD-coated PCBN tools. CIRP Ann Manuf Technol2016; 65: 89–92.
32.
VigneauJBordelPLeonardA. Influence of the microstructure of the composite ceramic tools on their performance when machining nickel alloys. Ann CIRP1987; 36: 13–16.
33.
NarutakiNYamaneYHayashiKet al.High-speed machining of Inconel718 with ceramic tools. Ann ClRP1993; 42: 103–106.
34.
KumarASDuraiARSornakumarT. Wear behaviour of alumina based ceramic cutting tools on machining steels. Tribol Int2006; 39: 191–197.
35.
El WardanyTElbestawiM. Prediction of tool failure rate in turning hardened steels. Int J Adv Manuf Technol1997; 13: 1–16.
36.
GongFZhaoJPangJ. Evolution of cutting forces and tool failure mechanisms in intermittent turning of hardened steel with ceramic tool. Int J Adv Manuf Technol2017; 89: 1603–1613.
37.
WangBYinWWangMet al.Edge chipping mechanism and failure time prediction on carbide cemented tool during drilling of CFRP/Ti stack. Int J Adv Manuf Technol2017; 91: 3015–3024.
38.
KongXYangLZhangHet al.Cutting performance and coated tool wear mechanisms in laser-assisted milling K24 nickel-based superalloy. Int J Adv Manuf Technol2015; 77: 2151–2163.
39.
LiHHeGQinXet al.Tool wear and hole quality investigation in dry helical milling of Ti-6Al-4 V alloy. Int J Adv Manuf Technol2014; 71: 1511–1523.
40.
SunFQuSPanYet al.Machining performance of a grooved tool in dry machining Ti-6Al-4 V. Int J Adv Manuf Technol2014; 73: 613–622.
41.
ZouBZhouHHuangCet al.Tool damage and machined-surface quality using hot-pressed sintering Ti(C7N3)/WC/TaC cermet cutting inserts for high-speed turning stainless steels. Int J Adv Manuf Technol2015; 79: 197–210.
42.
EzugwuEOWangZMMachadoAR. The machinability of nickel-based alloys: a review. J Mater Process Technol1999; 86: 1–16.
43.
CoelhoRTSilvaLRBraghiniAJet al.Some effects of cutting edge preparation and geometric modifications when turning INCONEL 718™ at high cutting speeds. J Mater Process Technol2004; 148: 147–153.
44.
BushlyaVZhouJAvdovicPet al.Wear mechanisms of silicon carbide-whisker-reinforced alumina (Al2O3–SiCw) cutting tools when high-speed machining aged Alloy 718. Int J Adv Manuf Technol2013; 68: 1083–1093.
45.
PandaASahooAKRoutAKet al.Investigation of flank wear in hard turning of AISI 52100 grade using multilayer coated carbide and mixed ceramic inserts. Proc Manuf2018; 20: 365–371.
46.
Shalaby MA, El Hakim MA, Abdelhameed MM, et al. Compensation of deflection-induced errors in high precision hard turning using a piezoelectric-based fast tool servo. In: 6th international conference on virtual machining process technology (VMPT), Montréal, 2017.
47.
Shalaby MA, El Hakim MA and Veldhuis SC. Effect of some machining variables on surface roughness in precision turning. In: Proceeding of 6th international conference on virtual machining process technology (VMPT), Montréal, 2017.
48.
ShalabyMAEl HakimMVeldhuisSet al.An investigation into the behavior of the cutting forces in precision turning. Int J Adv Manuf Technol2017; 90: 1605–1615.
49.
Fox-RabinovichGTottenG. Self-organization during friction: advanced surface-engineered materials and systems design, Boca Raton, FL: CRC Press, 2010.
50.
EguilazERechJArrazolaP. Characterization of friction coefficient and heat partition coefficient between an AISI4140 steel and a TiN-coated carbide – influence of (Ca, Mn, S) steel’s inclusions. Proc IMechE, Part J: J Engineering Tribology2010; 224: 1115–1127.
51.
Fox-RabinovichGYamamotoKBeakeDet al.Hierarchical adaptive nanostructured PVD coatings for extreme tribological applications: the quest for nonequilibrium states and emergent behavior. Sci Technol Adv Mater2012; 13: 043001–043001.
52.
YuanJYamamotoKCovelliDet al.Tribo-films control in adaptive TiAlCrSiYN/TiAlCrN multilayer PVD coating by accelerating the initial machining conditions. Surf Coat Technol2016; 294: 54–61.
53.
KitagawaTKuboAMaekawaK. Temperature and wear of cutting tools in high speed machining of inconel 718 and Ti-6Al-6 V-2Sn. Wear1997; 202: 142–148.
54.
TangLGaoCHuangJet al.Experimental investigation of surface integrity in finish dry hard turning of hardened tool steel at different hardness levels. Int J Adv Manuf Technol2015; 77: 1655–1669.
55.
GailianWCuiweiWMaicangZet al.The microstructural changes and their effect on CCGR after long time thermal exposure in DA718 and STD718. Mater Sci Eng A2003; 358: 71–75.
LynchSPRadtkeTCWicksBJet al.Fatigue crack grows in nickel-based superalloys at 500–700C. II: direct-aged alloy 718. Fatig Fract Eng Mater Struct1994; 17: 313–325.
58.
DosbaevaGKVeldhuisSCElfizyAet al.Microscopic observations on the origin of defects during machining of direct aged (DA) Inconel 718 superalloy. J Mater Eng Perform2010; 19: 1193–1198.
59.
Fox-RabinovichGSGershmanISYamamotoKet al.Surface/interface phenomena in nanomultilayer coating under severing tribological conditions. Surf Interf Anal2017; 49: 584–593.
