A Novel Approach for Dry Cutting Inconel 718 in a More Sustainable and Low-Cost Way by Actively and Purposely Utilizing the Built-Up Layer

Due to its physical and mechanical properties, Inconel 718 remains a difficult-to-cut material and there is an urgent need to develop a more sustainable and low-cost way to machine it. A novel approach for dry cutting Inconel 718 by actively and purposely utilizing the built-up layer (BUL), which ca...

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Bibliographic Details
Published in:Micromachines (Basel) 2023-09, Vol.14 (9), p.1787
Main Authors: Song, Xiaoqi, He, Weiming, Ihara, Tohru
Format: Article
Language:English
Subjects:
Adhesive wear
Analysis
built-up layer
Carbide tools
Carbon
Cemented carbides
Climate change
Consumption
Cutting force
Cutting parameters
Cutting tools
dry machining
Economic aspects
Friction reduction
Heat conductivity
Heat resistant alloys
Heat treating
Inconel 718
Low cost
Manufacturing
Mechanical properties
Methods
Nickel alloys
Nickel base alloys
Physical properties
self-protective effect
Stability analysis
Stainless steel
Superalloys
Surface roughness
Temperature
tool wear
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Summary:Due to its physical and mechanical properties, Inconel 718 remains a difficult-to-cut material and there is an urgent need to develop a more sustainable and low-cost way to machine it. A novel approach for dry cutting Inconel 718 by actively and purposely utilizing the built-up layer (BUL), which can be called the self-protective tool (SPT) method, is proposed and investigated in detail in this paper. Various cutting experiments were carried out using the age-treated Inconel 718 and uncoated cemented carbide tools. The formation condition of the BUL, its formation mechanism, its stability, and its protective effect were examined by measuring the tools after cutting using a scanning electron microscope (SEM) and laser confocal microscopy (LCM). The influences of BUL on the cutting process were investigated using cutting force analysis and surface roughness analysis. The results confirmed that the stability of the BUL is very high, and the BUL can not only significantly protect the tool from wear but also reduce friction at the tool–chip interface and maintain surface roughness. It also revealed that the height of the BUL can play a very important role in its protective effect. Comparative experiments verified the effectiveness and generalizability of the proposed SPT method.
ISSN:2072-666X
2072-666X
DOI:10.3390/mi14091787