Abstract
Machinability of Inconel-718 superalloy in conventional approach is poor—this fact necessitates advanced technological adoption such as improved surface topography over used cutting tool. Recently, the performance of textured tool has been investigated to explore its potential benefits in achieving favourability in machining of superalloy. In that context, the impact of tool texturing, cutting speed and machining time on some of the prominent machinability indices like cutting forces, tool wear, surface finish and chip morphology has been deliberately investigated. The performance comparison of non-textured and textured tool has been conducted at cutting speed of 80, 120 and 180 m min−1 and at successive increment of machining times up to 10 min. Moreover, the scanning electron microscope analysis of worn tool edges was carried out to comprehend the wear mechanism. Furthermore, the thermal analysis was done for dedicated textured tooling condition. Results revealed that the textured tool performs better to ensure lower tool wear (VB), reduced cutting forces (Fc), lower surface roughness (Ra) and acceptable form of chips. The spots of textured tool acted as fins to promote efficient heat transfer from cutting zone and reduced the effective chip–tool contact length to cause less friction.
Similar content being viewed by others
References
Bansal A, Sharma AK, Das S, Kumar P. On microstructure and strength properties of microwave welded Inconel 718/stainless steel (SS-316L). Proc Inst Mech Eng Part L J Mater Des Appl. 2015;230:939–48. https://doi.org/10.1177/1464420715589206.
Bhopale NN, Pawade RS, Joshi SS. Surface quality analysis in ball end milling of Inconel 718 cantilevers by response surface methodology. Proc Inst Mech Eng Part B J Eng Manuf. 2015;231:628–40. https://doi.org/10.1177/0954405415600140.
Unune DR, Mali HS. Experimental investigation on low-frequency vibration-assisted µ-ED milling of Inconel 718. Mater Manuf Process. 2018;33:964–76. https://doi.org/10.1080/10426914.2017.1388516.
Singh G, Gupta MK, Mia M, Sharma VS. Modeling and optimization of tool wear in MQL-assisted milling of Inconel 718 superalloy using evolutionary techniques. Int J Adv Manuf Technol. 2018;97:481–94. https://doi.org/10.1007/s00170-018-1911-3.
Moon S-H, Lee C-M. A study on the machining characteristics using plasma assisted machining of AISI 1045 steel and Inconel 718. Int J Mech Sci. 2018;142–143:595–602.
Antonialli AÍS, Magri A, Diniz AE. Tool life and tool wear in taper turning of a nickel-based superalloy. Int J Adv Manuf Technol. 2016;87:2023–32. https://doi.org/10.1007/s00170-016-8568-6.
Sarıkaya M, Güllü A. Multi-response optimization of minimum quantity lubrication parameters using Taguchi-based grey relational analysis in turning of difficult-to-cut alloy Haynes 25. J Clean Prod. 2015;91:347–57.
Yıldırım ÇV, Kıvak T, Sarıkaya M, Erzincanlı F. Determination of MQL parameters contributing to sustainable machining in the milling of nickel-base superalloy waspaloy. Arab J Sci Eng. 2017;42:4667–81. https://doi.org/10.1007/s13369-017-2594-z.
Sarıkaya M, Yılmaz V, Güllü A. Analysis of cutting parameters and cooling/lubrication methods for sustainable machining in turning of Haynes 25 superalloy. J Clean Prod. 2016;133:172–81.
Anamalai K, Samylingam L, Kadirgama K, Samykano M, Najafi G, Ramasamy D, et al. Multi-objective optimization on the machining parameters for bio-inspired nanocoolant. J Therm Anal Calorim. 2018. https://doi.org/10.1007/s10973-018-7693-x.
Mia M. Multi-response optimization of end milling parameters under through-tool cryogenic cooling condition. Measurement. 2017;111:134–45.
Gupta M, Pruncu C, Mia M, Singh G, Singh S, Prakash C, et al. Machinability investigations of Inconel-800 super alloy under sustainable cooling conditions. Materials (Basel). 2018;11:2088.
Mia M, Singh G, Gupta MK, Sharma VS. Influence of Ranque-Hilsch vortex tube and nitrogen gas assisted MQL in precision turning of Al 6061-T6. Precis Eng. 2018;53:289–99.
Mia M, Gupta MK, Singh G, Królczyk G, Pimenov DY. An approach to cleaner production for machining hardened steel using different cooling-lubrication conditions. J Clean Prod. 2018;187:1069–81.
Mia M, Morshed MS, Kharshiduzzaman M, Razi MH, Mostafa MR, Rahman SMS, et al. Prediction and optimization of surface roughness in minimum quantity coolant lubrication applied turning of high hardness steel. Measurement. 2018;118:43–51.
Jesudass Thomas S, Kalaichelvan K. Comparative study of the effect of surface texturing on cutting tool in dry cutting. Mater Manuf Process. 2018;33:683–94. https://doi.org/10.1080/10426914.2017.1376070.
Dinesh S, Senthilkumar V, Asokan P. Experimental studies on the cryogenic machining of biodegradable ZK60 Mg alloy using micro-textured tools. Mater Manuf Process. 2017;32:979–87. https://doi.org/10.1080/10426914.2016.1221096.
Thiyagu M, Karunamoorthy L, Arun Kumar N. Magnetorheological fluid-based nanotexturing of tool inserts for turning of duplex stainless steel. Mater Manuf Process. 2017;32:1019–25. https://doi.org/10.1080/10426914.2016.1257136.
Sharma V, Pandey PM. Comparative study of turning of 4340 hardened steel with hybrid textured self-lubricating cutting inserts. Mater Manuf Process. 2016;31:1904–16. https://doi.org/10.1080/10426914.2015.1127951.
Arulkirubakaran D, Senthilkumar V, Kumawat V. Effect of micro-textured tools on machining of Ti–6Al–4V alloy: an experimental and numerical approach. Int J Refract Met Hard Mater. 2016;54:165–77.
Lei S, Devarajan S, Chang Z. A study of micropool lubricated cutting tool in machining of mild steel. J Mater Process Technol. 2009;209:1612–20.
Obikawa T, Kamio A, Takaoka H, Osada A. Micro-texture at the coated tool face for high performance cutting. Int J Mach Tools Manuf. 2011;51:966–72.
Sugihara T, Enomoto T, Yukinaga S. Improving tool wear resistance in steel cutting by textured surface and its mechanism. Adv Mater Res. 2012;565:424–9.
Xie J, Luo MJ, Wu KK, Yang LF, Li DH. Experimental study on cutting temperature and cutting force in dry turning of titanium alloy using a non-coated micro-grooved tool. Int J Mach Tools Manuf. 2013;73:25–36.
Koshy P, Tovey J. Performance of electrical discharge textured cutting tools. CIRP Ann. 2011;60:153–6.
Ma J, Duong NH, Lei S. Numerical investigation of the performance of microbump textured cutting tool in dry machining of AISI 1045 steel. J Manuf Process. 2015;19:194–204.
Kim DM, Lee I, Kim SK, Kim BH, Park HW. Influence of a micropatterned insert on characteristics of the tool–workpiece interface in a hard turning process. J Mater Process Technol. 2016;229:160–71.
Gupta MK, Sood PK, Sharma VS. Investigations on surface roughness measurement in minimum quantity lubrication turning of titanium alloys using response surface methodology and Box-Cox transformation. J Manuf Sci Prod. 2016;16:75–88.
Mia M, Dhar NR. Influence of single and dual cryogenic jets on machinability characteristics in turning of Ti–6Al–4V. Proc Inst Mech Eng Part B J Eng Manuf. 2017;233:711–26. https://doi.org/10.1177/0954405417737581.
Gupta MK, Sood PK, Sharma VS. Machining parameters optimization of titanium alloy using response surface methodology and particle swarm optimization under minimum-quantity lubrication environment. Mater Manuf Process. 2016;31:1671–82. https://doi.org/10.1080/10426914.2015.1117632.
Gupta MK, Sood PK. Surface roughness measurements in NFMQL assisted turning of titanium alloys: an optimization approach. Friction. 2017;5:155–70.
Ferreira R, Carou D, Lauro CH, Davim JP. Surface roughness investigation in the hard turning of steel using ceramic tools. Mater Manuf Process. 2016;31:648–52. https://doi.org/10.1080/10426914.2014.995051.
Delahaigue J, Chatelain J-F, Lebrun G. Machining analysis of unidirectional and bi-directional flax-epoxy composite laminates. Proc Inst Mech Eng Part L J Mater Des Appl. 2017;231:196–209. https://doi.org/10.1177/1464420716671970.
Mohanty A, Gangopadhyay S, Thakur A. On applicability of multilayer coated tool in dry machining of aerospace grade stainless steel. Mater Manuf Process. 2016;31:869–79. https://doi.org/10.1080/10426914.2015.1070413.
Madyira DM, Laubscher RF, van Rensburg NJ, Henning PFJ. High speed machining induced residual stresses in Grade 5 titanium alloy. Proc Inst Mech Eng Part L J Mater Des Appl. 2012;227:208–15. https://doi.org/10.1177/1464420712462319.
Mehta A, Hemakumar S, Patil A, Khandke SP, Kuppan P, Oyyaravelu R, et al. Influence of sustainable cutting environments on cutting forces, surface roughness and tool wear in turning of Inconel 718. Mater Today Proc. 2018;5:6746–54.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Darshan, C., Jain, S., Dogra, M. et al. Machinability improvement in Inconel-718 by enhanced tribological and thermal environment using textured tool. J Therm Anal Calorim 138, 273–285 (2019). https://doi.org/10.1007/s10973-019-08121-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10973-019-08121-y