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EDS Analysis of Flank Wear and Surface Integrity in Machining of Alloy 718 with Forced Coolant Application
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). Swerea-KIMAB AB, 164 40, Stockholm, Sweden. (PTW)
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). (PTW)ORCID-id: 0000-0002-0895-3303
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). Swerea-IVF AB, 431 22, Mölndal, Sweden. (PTW)
Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). (PTW)ORCID-id: 0000-0003-0976-9820
Visa övriga samt affilieringar
2016 (Svenska)Ingår i: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 45, s. 271-274Artikel i tidskrift (Refereegranskat) Published
Abstract [en]

There has been extensive research on forced coolant application, usually known as high pressure coolant, in machining heat resistant super alloys. This technology has shown to improve the tool life, chip segmentation, surface integrity and reduce the temperature in the cutting zone. A number of studies have been done on hydraulic parameters of the coolant. This study has been focused on residues on the flank face of the insert and residual stress on the workpiece surface generated by regular and modified cutting inserts. To identify any residual elements, analysis were done by energy dispersive X-ray spectrometer, EDS, on regular as well as modified inserts in combination with forced coolant application on both rake and flank face. The investigations have shown that the temperature gradient in the insert has changed between the regular and modified cutting inserts and that the tool wear and surface roughness is significantly affected by the modified cutting tool.

Ort, förlag, år, upplaga, sidor
2016. Vol. 45, s. 271-274
Nyckelord [en]
EDS; Heat zone; Surface roughness; Residues; Facing; Forced coolant application; Residual stress
Nationell ämneskategori
Bearbetnings-, yt- och fogningsteknik
Forskningsämne
Produktionsteknik
Identifikatorer
URN: urn:nbn:se:hv:diva-10031DOI: 10.1016/j.procir.2016.02.144Scopus ID: 2-s2.0-84978639847OAI: oai:DiVA.org:hv-10031DiVA, id: diva2:1039223
Konferens
3rd CIRP Conference on Surface Integrity,
Forskningsfinansiär
Västra GötalandsregionenTillgänglig från: 2016-10-21 Skapad: 2016-10-21 Senast uppdaterad: 2019-11-18Bibliografiskt granskad
Ingår i avhandling
1. Textured insert for improved heat extraction in combination with high-pressure cooling in turning of superalloys
Öppna denna publikation i ny flik eller fönster >>Textured insert for improved heat extraction in combination with high-pressure cooling in turning of superalloys
2017 (Engelska)Licentiatavhandling, sammanläggning (Övrigt vetenskapligt)
Abstract [en]

Heat generated in a machining process is a common and critical obstacle faced in today's machining industries. The heat generated in the cutting zone has a direct negative influence on the tool life which, in turn contributes to increase the manufacturing costs. Especially, in machining of Heat Resistant Super Alloys, HRSA this is a very limiting factor. HRSA are capable of retaining their mechanical strength and hardness at elevated temperatures. This property is advantageous in the application in e.g. aero-engines but also a disadvantage, since it also lowers the machinability significantly. This work is an attempt to improve the heat transfer from the cutting zone, which would lead to an increase in the tool life. To achieve this goal, the cutting tool has been modified to create an improved interface between the coolant and tool in the high-temperature areas. Two generations of inserts have been designed and investigated. Firstly, an insert with surface texture features has been created with the purpose of increasing the available surface area for heat dissipation: First generation, Gen I. Secondly, a GenII was designed as a further improvement of Gen I. Here, several channel features on the rake face were added, reaching out from the contact zone to the near proximity of the cutting edge. This with the purpose of improving access of the coolant closer to the cutting edge. The experiments were conducted in facing operations of Alloy 718 with uncoated round carbide inserts. All experiments were carried out with high-pressure coolant assistance, with a pressure of 16 MPa on the rake face and 8 MPa on the flankface, respectively.The two generations of inserts, Gen I and Gen II, were experimentally evaluated by tool wear analysis in comparison with a regular insert. The results shows that the tool life increased significantly for the Gen I insert, compared to a catastrophic failure of the regular insert at the same conditions. Regarding the Gen II insert,an increase in tool life by approximately 30 to 40 percent compared to Gen I insert was observed.

Ort, förlag, år, upplaga, sidor
Trollhättan: University West, 2017. s. 90
Serie
Licentiate Thesis: University West ; 19
Nyckelord
Alloy 718; High-pressure coolant; Heat dissipation, Textured insert; Tungsten carbide, Tool life, Tool wear
Nationell ämneskategori
Bearbetnings-, yt- och fogningsteknik
Forskningsämne
Produktionsteknik
Identifikatorer
urn:nbn:se:hv:diva-11738 (URN)978-91-87531-63-7 (ISBN)978-91-87531-62-0 (ISBN)
Presentation
2017-10-12, F315, University West, Trollhättan, 13:00 (Engelska)
Handledare
Tillgänglig från: 2017-10-06 Skapad: 2017-10-06 Senast uppdaterad: 2017-10-06Bibliografiskt granskad
2. Enhanced heat transfer and tool wear in high-pressure coolant assisted turning of alloy 718
Öppna denna publikation i ny flik eller fönster >>Enhanced heat transfer and tool wear in high-pressure coolant assisted turning of alloy 718
2019 (Engelska)Doktorsavhandling, sammanläggning (Övrigt vetenskapligt)
Alternativ titel[sv]
Förbättrad värmeavledning och verktygsslitage vid högtryckskyld svarvning av legering 718
Abstract [en]

Heat generated in a machining process is a common and critical obstacle faced in today's manufacturing industries. The heat generated in the cutting zone has adirect negative influence on the tool life, which, in turn contributes to increasing the manufacturing costs. Especially in the machining of Heat Resistant Superalloys, HRSA, this is a very limiting factor. HRSA are capable of retaining their mechanical strength and hardness at elevated temperatures. This property is advantageous for applications such as aero-engines, but also a disadvantage, since it also lowers the machinability significantly.This work is an attempt to improve the heat transfer from the cutting zone, which would lead to an increase in the tool life. To achieve this goal, the effect of cooling the flank face (tertiary shear zone) with high-pressure is studied; furthermore, the cutting tool has been modified to create an improved interface between the high pressure coolant and the tool where high-temperature gradient exists.Three main generations of inserts have been designed and investigated. Firstly, an insert with surface texture features created with the purpose of increasing the available surface area for heat dissipation: First generation, Gen I. Secondly, GenI+, a modified rake design of Gen I, for improved frictional conditions on the tool-chip contact. Thirdly, Gen II was designed as a further improvement of GenI. Here, several channel features on the rake face were added, reaching out from the contact zone to the near proximity of the cutting edge. This has the purpose of improving access of the coolant closer to the cutting edge.The experiments were conducted in facing operations of Alloy 718 with uncoated round carbide inserts. All experiments were carried out with high-pressure coolant, with a maximum available pressure of 16 MPa on the rake face and 8MPa on the flank face, respectively. The three generations of inserts, Gen I, I+and II, were experimentally evaluated by tool wear analysis in comparison with a regular insert. The results shows that the tool life increased significantly for the Gen I insert, compared to catastrophic failure of the regular insert at the same conditions. Regarding the Gen II insert, an increase in tool life by approximately30-40 percent, compared to Gen I inserts was observed. XRegarding the coolant-boiling phenomenon, results revealed the existence in form of dark region (Ca precipitate) below the flank wear land. The location and size of the coolant-boiling region is interrelated between flank wear, cutting zone temperature, coolant pressure and vapour pressure of the coolant at the investigated coolant pressure levels. The coolant applied at a pressure lower than the vapour pressure of the coolant itself will cause the "Leidenfrost effect" to appear that will effectively act as a coolant barrier region. However, most importantly, this effect led to the observation of a new wear mechanism present "Cavitation Wear". This type of wear appears in the form of erosion pits on the flank surface of the insert and it is observed for flank pressure conditions of 4and 8 MPa. It is a new phenomenon in tool wear to be seen on uncoated WC cutting tools during machining operations with high-pressure coolant.

Ort, förlag, år, upplaga, sidor
Trollhättan: University West, 2019. s. 118
Serie
PhD Thesis: University West ; 31
Nyckelord
Alloy 718; Cavitation; Coolant-boiling; High-pressure coolant; Heat dissipation, Leidenfrost effect; Textured insert; Tungsten carbide; Tool life; Tool wear
Nationell ämneskategori
Bearbetnings-, yt- och fogningsteknik
Forskningsämne
Produktionsteknik; TEKNIK, Produktions- och materialteknik
Identifikatorer
urn:nbn:se:hv:diva-14663 (URN)978-91-88847-42-3 (ISBN)978-91-88847-41-6 (ISBN)
Disputation
2019-11-22, Albertssalen, 10:00 (Engelska)
Opponent
Handledare
Tillgänglig från: 2019-10-30 Skapad: 2019-10-30 Senast uppdaterad: 2019-10-30Bibliografiskt granskad

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