Effect of cutting speed and CVD multilayer coating on machinability of Inconel 825

Abstract

The current study aims at investigating the effect of cutting speed (51, 84 and 124 m min⁻¹) as well as tool coating deposited using chemical vapour deposition (CVD) on machined surface roughness, tool wear characteristics, chip morphology and chip reduction coefficient (ζ) during dry machining of Inconel 825. Turning operation was carried out using ISO P30 uncoated cemented carbide and CVD multilayer coated (TiN/TiCN/Al₂O₃/ZrCN) insert with a constant feedrate of 0·198 mm rev⁻¹ and depth of cut of 1 mm. Chip morphology and tool wear were studied using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and optical microscopy. Results indicated CVD multilayer coated tool resulted in more machined surface roughness compare to it uncoated counterpart. However, coated tool demonstrated excellent resistance to crater and flank wear, and decrease in chip reduction coefficient during dry machining of Inconel 825.

Keywords

Multilayer coating Cemented carbide Inconel 825 Chip morphology Chip reduction coefficient Tool wear

Get full access to this article

View all access options for this article.

References

Zhu

, Zhang

and Ding

: ‘Tool wear characteristics in machining of nickel-based superalloys’, Int. J. Mach. Tools Manuf., 2013, 64, 60–77.

Ezugwu

: ‘Key improvements in the machining of difficult-to-cut aerospace superalloys’, Int. J. Mach. Tools Manuf., 2005, 45, 1353–1367.

Ezugwu

, Bonney

and Yamane

: ‘An overview of the machinability of aeroengine alloys’, J. Mater. Processes Technol., 2003, 134, 233–253.

Aytekin

and Akcin

: ‘Characterization of borided Incoloy 825 alloy’, Mater. Des., 2013, 50, 515–521.

Obikawa

, Kamata

, Asano

, Nakayama

and Otieno

: ‘Micro-liter lubrication machining of Inconel 718’, Int. J. Mach. Tools Manuf., 2008, 48, 1605–1612.

Costes

, Guillet

, Poulachon

and Dessoly

: ‘Tool-life and wear mechanisms of CBN tools in machining of Inconel 718’, Int. J. Mach. Tools Manuf., 2007, 47, 1081–1087.

Ezugwu

, Wang

and Okeke

: ‘Tool life and surface integrity when machining Inconel 718 with PVD and CVD coated tools’, Tribol. Trans., 1999, 42, 353–360.

Devillez

, Schneider

, Dominiak

, Dudzinski

and Larrouquere

: ‘Cutting forces and wear in dry machining of Inconel 718 with coated carbide tools’, Wear, 2007, 262, 931–942.

Bhatt

, Attia

, Vargas

and Thomson

: ‘Wear mechanisms of WC coated and uncoated tools in finish turning of Inconel 718’, Tribol. Int., 2010, 43, 1113–1121.

10.

Thakur

, Ramamoorthy

and Vijayaraghavan

: ‘Study on the machinability characteristics of superalloy Inconel 718 during high speed turning’, Mater. Des., 2009, 30, (5), 1718–1725.

11.

Thakur

, Ramamoorthy

and Vijayaraghavan

: ‘Machinability investigation of Inconel 718 in high-speed turning’, Int. J. Adv. Manuf. Technol., 2009, 45, (5–6), 421–429.

12.

Pawade

and Joshi

: ‘Mechanism of chip formation in high-speed turning of Inconel 718’, Mach. Sci. Technol., 2011, 15, 132–152.

13.

Jin

and Liu

: ‘Effect of cutting speed on surface integrity and chip morphology in high-speed machining of PM nickel-based superalloy FGH95’, Int. J. Adv. Manuf. Technol., 2012, 60, 893–899.

14.

Wang

, Xie

, Zheng

, Qin

, Tang

and Song

: ‘Research on the chip formation mechanism during the high-speed milling of hardened steel’, Int. J. Mach. Tools Manuf., 2014, 79, 31–48.

15.

Sahoo

and Sahoo

: ‘Experimental investigations on machinability aspects in finish hard turning of AISI 4340 steel using uncoated and multilayer coated carbide inserts’, Measurement, 2012, 45, (8), 2153–2165.

16.

Khidhir

and Mohamed

: ‘Study of cutting speed on surface roughness and chip formation when machining nickel-based alloy’, J. Mech. Sci. Technol., 2010, 24, (5), 1053–1059.

17.

Narasimhan

and Russell

: ‘Multilayer CVD coated article and process for producing same’, US Patent 20010016273 A1, 2001.

18.

Bushlya

, Zhou

and Stahl

: ‘Effect of cutting conditions on machinability of superalloy Inconel 718 during high speed turning with coated and uncoated PCBN tools’, Proc. CIRP, 2012, 3, 370–375.

19.

Zhou

, Bushlya

, Avdovic

and Stahl

: ‘Study of surface quality in high speed turning of Inconel 718 with uncoated and coated CBN tools’, Int. J. Adv. Manuf. Technol., 2012, 58, (1–4), 141–151.

20.

Vyas

and Shaw

: ‘Mechanics of saw-tooth chip formation in metal cutting’, J. Manuf. Sci. Eng., 1999, 121, (2), 163–172.

21.

and Liu

: ‘Analytical and experimental study on formation of concentrated shear band of saw tooth chip in high-speed machining’, Int. J. Adv. Manuf. Technol., 2013, 65, 1735–1740.

22.

Dhar

, Ahmed

and Islam

: ‘An experimental investigation on effect of minimum quantity lubrication in machining AISI 1040 steel’, Int. J. Mach. Tools Manuf., 2007, 47, (5), 748–753.

23.

Varadarajan

, Philip

and Ramamoorthy

: ‘Investigations on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning’, Int. J. Mach. Tools Manuf., 2002, 42, 193–200.