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A detailed investigation of residual stresses after milling Inconel 718 using typical production parameters for assessment of affected depth
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. RISE IVF AB, Argongatan 30, Mölndal, 431 53, Sweden. (PTW)ORCID iD: 0000-0003-2991-2911
GKN Aerospace Sweden AB, Trollhättan, 461 81, Sweden.
RISE IVF AB, Argongatan 30, Mölndal, 431 53, Sweden.
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0003-0976-9820
2020 (English)In: Materials Today Communications, ISSN 2352-4928, Vol. 24, article id 100958Article in journal (Refereed) Published
Abstract [en]

Production of superalloy gas turbine parts involves time consuming milling operations typically performed in a sequence from rough to finish milling. Rough milling using ceramic inserts allows high removal rates but causes severe sub-surface impact. A relatively large allowance is therefore left for subsequent cemented carbide milling. With increased knowledge of the affected depth it will be possible to reduce the machining allowance and increase efficiency of the manufacturing process. Milling Inconel 718 using typical production parameters has been investigated using new and worn ceramic and cemented carbide inserts. Residual stresses in a milled slot were measured by x-ray diffraction. Stresses were measured laterally across the slot and below the surface, to study the depth affected by milling. The most important result from this work is the development of a framework concerning how to evaluate the affected depth for a milling operation. The evaluation of a single milled slot shows great potential for determining the optimum allowance for machining. Our results show that the residual stresses are greatly affected by the ceramic and cemented carbide milling; both regarding depth as well as distribution across the milled slot. It has been shown that it is important to consider that the stresses across a milled slot are the highest in the center of the slot and gradually decrease toward the edges. Different inserts, ceramic and cemented carbide, and tool wear, alter how the stresses are distributed across the slot and the affected depth. © 2020 The Authors

Place, publisher, year, edition, pages
2020. Vol. 24, article id 100958
Keywords [en]
Carbide cutting tools; Carbide tools; Carbides; Milling (machining); Residual stresses, Allowance determination; Alloy 718; High speed milling; Material removal rate; Surface integrity, Cutting tools
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-14992DOI: 10.1016/j.mtcomm.2020.100958ISI: 000571070900004Scopus ID: 2-s2.0-85079036532OAI: oai:DiVA.org:hv-14992DiVA, id: diva2:1395753
Available from: 2020-02-24 Created: 2020-02-24 Last updated: 2020-11-15Bibliographically approved
In thesis
1. High volumetric machining strategies for superalloy gasturbine components: Comparing conventional and nonconventional machining methods for efficient manufacturing
Open this publication in new window or tab >>High volumetric machining strategies for superalloy gasturbine components: Comparing conventional and nonconventional machining methods for efficient manufacturing
2020 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

There is a strong industrial driving force to find alternative manufacturing technologies in order to make the production of aero engine components of superalloys even more efficient than it is today. Introducing new and nonconventional machining technologies, as well as enhanced utilisation of today's high volumetric manufacturing, allows taking a leap to increase the material removal rate and the productivity. However, the final goal is to meet there quirements set for today's machined surfaces.The objective with the present work has been performed to show how the conventional, Milling, and the non-conventional machining methods, Abrasive Water Jet Machining, AWJM, Laser Beam Machining, LBM, and Electrical Discharge Machining, EDM, affect the surface integrity. This knowledge can beused to define and optimise different manufacturing alternatives for existing orfuture production.The results show that it is possible to use the rough milling to a greater extent if the impact on residuals stresses and deformation is used when determine the machining allowance. This could have a great impact on the productivity.

However, further improvement of the productivity requires an alternative method. For this reason, EDM and AWJM was evaluated and shown to be suitable alternatives to today's manufacturing methods, but both methods require post processing. The results showed that a combination of two post processes is required for addressing issues with residue, topography and residual stresses.The most promising and effective manufacturing strategy would be EDM or AWJM for rough machining followed by post processing either by finish millingor post processing by means of High-Pressure Water Jet Cleaning and shot peening. If EDM and AWJM are to be considered as finish machining operations, further development of the two methods are required.

Place, publisher, year, edition, pages
Trollhättan: University West, 2020. p. 121
Series
PhD Thesis: University West ; 40
Keywords
Alloy 718, High volumetric machining, Conventional and Nonconventional machining, Material removal rate, Post processing, surface integrity, Residual stress, Microstructure, Deformation
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-16010 (URN)978-91-88847-75-1 (ISBN)978-91-88847-74-4 (ISBN)
Public defence
2020-11-04, Albertssalen, 10:00 (English)
Opponent
Supervisors
Available from: 2020-11-11 Created: 2020-11-10 Last updated: 2020-11-10Bibliographically approved

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Holmberg, JonasBeno, Tomas

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