Title: Chip morphology and surface roughness in high-speed milling of nickel-based superalloy Inconel 718

Authors: Fuda Ning; Fuji Wang; Zhenyuan Jia; Jianwei Ma

Addresses: School of Mechanical Engineering, Dalian University of Technology, No. 2, Linggong Road, Ganjingzi District, Dalian, 116024, China ' School of Mechanical Engineering, Dalian University of Technology, No. 2, Linggong Road, Ganjingzi District, Dalian, 116024, China ' School of Mechanical Engineering, Dalian University of Technology, No. 2, Linggong Road, Ganjingzi District, Dalian, 116024, China ' School of Mechanical Engineering, Dalian University of Technology, No. 2, Linggong Road, Ganjingzi District, Dalian, 116024, China

Abstract: Chip formation process can lead to the fluctuation of cutting force and result in cutting vibration during high-speed milling, which makes serious impact on surface quality. In this paper, chip formation process is analysed and experiments are carried out to investigate the evolution of chip morphology and its effect on surface roughness in high-speed milling of nickel-based superalloy. It is found that, as the cutting speed increases from 25 to 200 m/min, the value of chip burrs firstly decreases and then increases. Chip morphology is gradually transformed from ribbon to serration. At the critical cutting speed of 75 m/min, both pitch and height of chip burrs reach the lowest value and serrated chips begin to appear. The variation tendency of surface roughness values agrees well with the evolution of chip morphology. The experimental results have a great significance for improving the surface quality in high-speed milling of nickel-based superalloy.

Keywords: nickel-based superalloys; Inconel 718; high speed milling; cutting speed; chip formation; chip burrs; serrated chip morphology; surface quality; surface roughness; coating carbide tools; cutting vibration; high speed machining.

DOI: 10.1504/IJMMM.2014.060554

International Journal of Machining and Machinability of Materials, 2014 Vol.15 No.3/4, pp.285 - 299

Available online: 19 Apr 2014 *

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