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EDS Analysis of Flank Wear and Surface Integrity in Machining of Alloy 718 with Forced Coolant Application
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Swerea-KIMAB AB, 164 40, Stockholm, Sweden. (PTW)
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0002-0895-3303
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Swerea-IVF AB, 431 22, Mölndal, Sweden. (PTW)
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)
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2016 (Swedish)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 45, 271-274 p.Article in journal (Refereed) 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.

Place, publisher, year, edition, pages
Elsevier, 2016. Vol. 45, 271-274 p.
Keyword [en]
EDS; Heat zone; Surface roughness; Residues; Facing; Forced coolant application; Residual stress
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-10031DOI: 10.1016/j.procir.2016.02.144Scopus ID: 2-s2.0-84978639847OAI: oai:DiVA.org:hv-10031DiVA: diva2:1039223
Conference
3rd CIRP Conference on Surface Integrity,
Available from: 2016-10-21 Created: 2016-10-21 Last updated: 2017-10-06Bibliographically approved
In thesis
1. Textured insert for improved heat extraction in combination with high-pressure cooling in turning of superalloys
Open this publication in new window or tab >>Textured insert for improved heat extraction in combination with high-pressure cooling in turning of superalloys
2017 (English)Licentiate thesis, comprehensive summary (Other academic)
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.

Place, publisher, year, edition, pages
Trollhättan: University West, 2017. 90 p.
Series
Licentiate Thesis: University West, 19
Keyword
Alloy 718; High-pressure coolant; Heat dissipation, Textured insert; Tungsten carbide, Tool life, Tool wear
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
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 (English)
Supervisors
Available from: 2017-10-06 Created: 2017-10-06 Last updated: 2017-10-06Bibliographically approved

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