Investigation of surface topology in ball nose end milling process of Inconel 718

Investigation of surface topology in ball nose end milling process of Inconel 718

Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep resistance, high fatigue strength, and able to withstand at elevated temperature which remains as challenge to possesses a lower surface roughness (Ra) during machining. The surface topology indicates the...

Full description

Saved in:
Bibliographic Details
Published in:Wear Vol. 426-427; pp. 1318 - 1326
Main Authors: Kasim, M.S., Hafiz, M.S.A., Ghani, J.A., Haron, C.H.C., Izamshah, R., Sundi, S.A., Mohamed, S.B., Othman, I.S.
Format: Journal Article
Language:English
Published: Amsterdam Elsevier B.V 30-04-2019
Elsevier Science Ltd
Subjects:
Abrasion
Ball nose end milling
Creep strength
Cutting speed
End milling cutters
Fatigue strength
Feed direction
Feed rate
High speed machining
High temperature
Inconel 718
Mechanical properties
Milling (machining)
Nickel base alloys
Nose
Notch wear
Product design
Superalloys
Surface roughness
Surface topology
Third body abrasion
Topology
Tungsten carbide
Workpieces
Ball nose end milling
High speed machining
Third body abrasion
Inconel 718
Surface topology
Notch wear
Online Access:Get full text
Tags: Add Tag
No Tags, Be the first to tag this record!
Description
Summary:Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep resistance, high fatigue strength, and able to withstand at elevated temperature which remains as challenge to possesses a lower surface roughness (Ra) during machining. The surface topology indicates the integrity of the machined parts. The quality of the Inconel 718 surface during end milling process was investigated. The experiments involved the use of PVD coated with TiAlN/ AlCrN ball nose tungsten carbide with varying of cutting speeds (Vc) ranging between 100 and 140 m/min, a feed rate (fz) of 0.1–0.2 mm/tooth, and an axial depth of cut (DoC) of 0.5–1.0 mm. The effects of the width of cut (WoC) between 0.2 and 1.8 mm were carried out. Due to the profile of the milled surface is complex; some variations in gap distance on the spiral profile were detected. The cutting path area to be found that, the new cut is overlapped which generate a new surface roughness by eliminating the previous cut thus the non-uniform feed marks being created on the machined surface. The surface roughness measured in feed direction was found to be lowered than pick a direction. Furthermore it was found that the WoC are causes the variation in Ra. During machining at low feed rates, the phenomenon of carbide particles was observed which results third body abrasion of machined surface. The particles are then trapped between the fragments and tear surface of the workpiece, thus increases the surface roughness. Based on the interaction effect of WoC and fz, it can be concluded that the feed rate effects on the quality of machined surface whilst WoC controls Ra variation. •The rotational and linear cutter motion causes inconsistent topology profile.•Width of cut controls surface roughness variations of the milled surface.•Lower Ra value caused by the smeared material at the edge of the cutter path.•Notch wear at the depth of cut line does not effect on the surface roughness.
ISSN:0043-1648
1873-2577
DOI:10.1016/j.wear.2018.12.076