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Next Generation Insert for Forced Coolant Application in Machining of Inconel 718
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. (PTW)
GKN Aerospace Engine Systems AB, Trollhättan, Sweden.
2016 (English)In: Materials Science Forum, ISSN 0255-5476, E-ISSN 1662-9752, Vol. 836-837, 340-347 p.Article in journal (Refereed) Published
Abstract [en]

Machining technology has undergone an extensive evolution throughout the last decades in its capability to machine hard-to-cut material. This paper will discuss about the next generation insert with cooling feature coupled with forced coolant in machining Inconel 718. The geometry of the insert was changed in a way which has enlarged the surface area approximately 12% compared to regular insert named as nusselt insert. The idea applied in “nusselt insert” was the relation of increase in surface area to heat dissipation. Forced coolant application has become a way to improve existing metal cutting concepts and improve their current material removal rates without any need for a reengineered machining process. Experiments conducted on the inserts is that the first experiment of its kind in machining technology together with forced coolant and tested in four different inserts. The primary focus of the work was the investigation of the relation between the heat dissipation with an increase in surface area/mass ratio in the cutting interface based on its influence on tool wear. The experimental results showed the nusselt insert have better ability for heat dissipation which has led to significant reduce in tool wear and successfully facing Inconel 718 at vc 105 m/min, f 0.3 mm/rev and ap 1 mm where the regular insert had a catastrophic failure at vc 90 m/min, f 0.1 mm/rev and ap 1 mm. Nusselt insert has shown to increase MRR significantly compared to regular insert.

Place, publisher, year, edition, pages
Trans Tech Publications Inc., 2016. Vol. 836-837, 340-347 p.
Keyword [en]
Tool wear, Heat dissipation, Inconel 718, Turning, Forced Coolant Application
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-8767DOI: 10.4028/www.scientific.net/MSF.836-837.340Scopus ID: 2-s2.0-84958074091OAI: oai:DiVA.org:hv-8767DiVA: diva2:877541
Conference
12th International Conference on High Speed Machining, HSM 2015; Nanjing; China; 18 October 2015 through 20 October 2015
Available from: 2015-12-07 Created: 2015-12-07 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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Tamil Alagan, Nageswaran

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