Article: High speed machining of nickel-based alloys Journal: International Journal of Mechatronics and Manufacturing Systems (IJMMS) 2015 Vol.8 No.1/2 pp.3 - 18 Abstract: The connection between rotor disc and blades in turbine applications is usually realised by complex profiled grooves. The profiled grooves are mostly manufactured by broaching processes. In compressor and fan applications, alternative cutting processes such as milling and broaching with more advanced cutting materials are already implemented. In turbine applications, where nickel-based alloys are used due to high forces and temperatures, the use of HSS-tools is still state of the art. Due to the low high temperature strength of this cutting material, cutting speeds do not exceed vc = 2-5 m/min. The use of alternative manufacturing processes for roughing therefore has a high potential. This paper presents experimental results on rough side milling of nickel-based alloys with whisker reinforced ceramics at cutting speeds up to vc = 1,500 m/min including wear behaviour and metallographic analysis. The results are compared to further alternative processes discussed to complement the broaching of profiled grooves and broaching with alternative tool grades. Inderscience Publishers - linking academia, business and industry through research

Title: High speed machining of nickel-based alloys

Authors: Fritz Klocke; Dieter Lung; Marvin Binder; Martin Seimann

Addresses: Laboratory for Machine Tools and Production Engineering, RWTH Aachen University, Steinbachstraße 19, D – 52074 Aachen, Germany ' Laboratory for Machine Tools and Production Engineering, RWTH Aachen University, Steinbachstraße 19, D – 52074 Aachen, Germany ' Laboratory for Machine Tools and Production Engineering, RWTH Aachen University, Steinbachstraße 19, D – 52074 Aachen, Germany ' Laboratory for Machine Tools and Production Engineering, RWTH Aachen University, Steinbachstraße 19, D – 52074 Aachen, Germany

Abstract: The connection between rotor disc and blades in turbine applications is usually realised by complex profiled grooves. The profiled grooves are mostly manufactured by broaching processes. In compressor and fan applications, alternative cutting processes such as milling and broaching with more advanced cutting materials are already implemented. In turbine applications, where nickel-based alloys are used due to high forces and temperatures, the use of HSS-tools is still state of the art. Due to the low high temperature strength of this cutting material, cutting speeds do not exceed v_c = 2-5 m/min. The use of alternative manufacturing processes for roughing therefore has a high potential. This paper presents experimental results on rough side milling of nickel-based alloys with whisker reinforced ceramics at cutting speeds up to v_c = 1,500 m/min including wear behaviour and metallographic analysis. The results are compared to further alternative processes discussed to complement the broaching of profiled grooves and broaching with alternative tool grades.

Keywords: high speed machining; broaching; rough side milling; nickel-based alloys; roughing; whisker reinforced ceramics; cutting speeds; wear behaviour; metallography; rotor discs; turbine blades; profiled grooves.

DOI: 10.1504/IJMMS.2015.071687

International Journal of Mechatronics and Manufacturing Systems, 2015 Vol.8 No.1/2, pp.3 - 18

Received: 20 Nov 2014
Accepted: 05 May 2015
Published online: 14 Sep 2015 *

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Title: High speed machining of nickel-based alloys

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