Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool
Understanding how feed rate (ft) affects tool deterioration during milling of Ni-based superalloys is practically important, but this understanding is currently insufficient. In the present study using a 718Plus Ni-based alloy and cemented tungsten carbide tool inserts, milling experiments were cond...
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doaj-58823802d5cd4bc3bc31647237d0b7db2020-11-25T01:05:47ZengMDPI AGMetals2075-47012017-10-0171044110.3390/met7100441met7100441Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide ToolNurul H. Razak0Zhan W. Chen1Timotius Pasang2Department of Mechanical Engineering, Auckland University of Technology, Auckland 1010, New ZealandDepartment of Mechanical Engineering, Auckland University of Technology, Auckland 1010, New ZealandDepartment of Mechanical Engineering, Auckland University of Technology, Auckland 1010, New ZealandUnderstanding how feed rate (ft) affects tool deterioration during milling of Ni-based superalloys is practically important, but this understanding is currently insufficient. In the present study using a 718Plus Ni-based alloy and cemented tungsten carbide tool inserts, milling experiments were conducted with ft = 0.10 mm/tooth under either dry or wet (with coolant) conditions. The results are compared to those based on using ft = 0.05 mm/tooth from previous studies. The milling force (F) was monitored, the cutting tool edge was examined and the flank wear (VBmax) was measured. As would be expected, an increase in ft increased F. It was found that F correlated well with VBmax for the high ft (0.1 mm/tooth) experiments, as opposed to the previously observed poor F-VBmax relationship for the lower ft (0.05 mm/tooth) value. This is explained, supported by detailed failure analysis of the cutting tool edges, by the deterioration mode to be dominantly edge chipping with a low occurrence of fracturing along the flank face when the high ft was used. This dominancy of the deterioration mode means that the tool edge and workpiece contact was consistent and thus resulted in a clear F-VBmax relationship. A clear F-VBmax relationship should then mean monitoring VBmax through monitoring F is possible.https://www.mdpi.com/2075-4701/7/10/441Ni-superalloytool deteriorationcutting forcewear monitoring |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Nurul H. Razak Zhan W. Chen Timotius Pasang |
spellingShingle |
Nurul H. Razak Zhan W. Chen Timotius Pasang Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool Metals Ni-superalloy tool deterioration cutting force wear monitoring |
author_facet |
Nurul H. Razak Zhan W. Chen Timotius Pasang |
author_sort |
Nurul H. Razak |
title |
Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool |
title_short |
Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool |
title_full |
Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool |
title_fullStr |
Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool |
title_full_unstemmed |
Effects of Increasing Feed Rate on Tool Deterioration and Cutting Force during End Milling of 718Plus Superalloy Using Cemented Tungsten Carbide Tool |
title_sort |
effects of increasing feed rate on tool deterioration and cutting force during end milling of 718plus superalloy using cemented tungsten carbide tool |
publisher |
MDPI AG |
series |
Metals |
issn |
2075-4701 |
publishDate |
2017-10-01 |
description |
Understanding how feed rate (ft) affects tool deterioration during milling of Ni-based superalloys is practically important, but this understanding is currently insufficient. In the present study using a 718Plus Ni-based alloy and cemented tungsten carbide tool inserts, milling experiments were conducted with ft = 0.10 mm/tooth under either dry or wet (with coolant) conditions. The results are compared to those based on using ft = 0.05 mm/tooth from previous studies. The milling force (F) was monitored, the cutting tool edge was examined and the flank wear (VBmax) was measured. As would be expected, an increase in ft increased F. It was found that F correlated well with VBmax for the high ft (0.1 mm/tooth) experiments, as opposed to the previously observed poor F-VBmax relationship for the lower ft (0.05 mm/tooth) value. This is explained, supported by detailed failure analysis of the cutting tool edges, by the deterioration mode to be dominantly edge chipping with a low occurrence of fracturing along the flank face when the high ft was used. This dominancy of the deterioration mode means that the tool edge and workpiece contact was consistent and thus resulted in a clear F-VBmax relationship. A clear F-VBmax relationship should then mean monitoring VBmax through monitoring F is possible. |
topic |
Ni-superalloy tool deterioration cutting force wear monitoring |
url |
https://www.mdpi.com/2075-4701/7/10/441 |
work_keys_str_mv |
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