Investigation of surface topology in ball nose end milling process of Inconel 718

M. S. Kasim, M. S.A. Hafiz, Jaharah A Ghani, Che Hassan Che Haron, R. Izamshah, S. A. Sundi, S. B. Mohamed, I. S. Othman

Research output: Contribution to journalArticle

1 Citation (Scopus)

Abstract

Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep resistance, high fatigue strength, and able to withstand at elevated temperature which remains as challenge to possesses a lower surface roughness (Ra) during machining. The surface topology indicates the integrity of the machined parts. The quality of the Inconel 718 surface during end milling process was investigated. The experiments involved the use of PVD coated with TiAlN/ AlCrN ball nose tungsten carbide with varying of cutting speeds (Vc) ranging between 100 and 140 m/min, a feed rate (fz) of 0.1–0.2 mm/tooth, and an axial depth of cut (DoC) of 0.5–1.0 mm. The effects of the width of cut (WoC) between 0.2 and 1.8 mm were carried out. Due to the profile of the milled surface is complex; some variations in gap distance on the spiral profile were detected. The cutting path area to be found that, the new cut is overlapped which generate a new surface roughness by eliminating the previous cut thus the non-uniform feed marks being created on the machined surface. The surface roughness measured in feed direction was found to be lowered than pick a direction. Furthermore it was found that the WoC are causes the variation in Ra. During machining at low feed rates, the phenomenon of carbide particles was observed which results third body abrasion of machined surface. The particles are then trapped between the fragments and tear surface of the workpiece, thus increases the surface roughness. Based on the interaction effect of WoC and fz, it can be concluded that the feed rate effects on the quality of machined surface whilst WoC controls Ra variation.

Original languageEnglish
JournalWear
DOIs
Publication statusAccepted/In press - 1 Jan 2018

Fingerprint

Inconel (trademark)
balls
topology
Topology
surface roughness
Surface roughness
machining
Machining
creep strength
Creep resistance
tungsten carbides
Tungsten carbide
abrasion
Physical vapor deposition
teeth
profiles
Abrasion
carbides
integrity
Carbides

Keywords

  • Ball nose end milling
  • High speed machining
  • Inconel 718
  • Notch wear
  • Surface topology
  • Third body abrasion

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Surfaces and Interfaces
  • Surfaces, Coatings and Films
  • Materials Chemistry

Cite this

Investigation of surface topology in ball nose end milling process of Inconel 718. / Kasim, M. S.; Hafiz, M. S.A.; A Ghani, Jaharah; Che Haron, Che Hassan; Izamshah, R.; Sundi, S. A.; Mohamed, S. B.; Othman, I. S.

In: Wear, 01.01.2018.

Research output: Contribution to journalArticle

Kasim, M. S. ; Hafiz, M. S.A. ; A Ghani, Jaharah ; Che Haron, Che Hassan ; Izamshah, R. ; Sundi, S. A. ; Mohamed, S. B. ; Othman, I. S. / Investigation of surface topology in ball nose end milling process of Inconel 718. In: Wear. 2018.
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abstract = "Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep resistance, high fatigue strength, and able to withstand at elevated temperature which remains as challenge to possesses a lower surface roughness (Ra) during machining. The surface topology indicates the integrity of the machined parts. The quality of the Inconel 718 surface during end milling process was investigated. The experiments involved the use of PVD coated with TiAlN/ AlCrN ball nose tungsten carbide with varying of cutting speeds (Vc) ranging between 100 and 140 m/min, a feed rate (fz) of 0.1–0.2 mm/tooth, and an axial depth of cut (DoC) of 0.5–1.0 mm. The effects of the width of cut (WoC) between 0.2 and 1.8 mm were carried out. Due to the profile of the milled surface is complex; some variations in gap distance on the spiral profile were detected. The cutting path area to be found that, the new cut is overlapped which generate a new surface roughness by eliminating the previous cut thus the non-uniform feed marks being created on the machined surface. The surface roughness measured in feed direction was found to be lowered than pick a direction. Furthermore it was found that the WoC are causes the variation in Ra. During machining at low feed rates, the phenomenon of carbide particles was observed which results third body abrasion of machined surface. The particles are then trapped between the fragments and tear surface of the workpiece, thus increases the surface roughness. Based on the interaction effect of WoC and fz, it can be concluded that the feed rate effects on the quality of machined surface whilst WoC controls Ra variation.",
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AU - Hafiz, M. S.A.

AU - A Ghani, Jaharah

AU - Che Haron, Che Hassan

AU - Izamshah, R.

AU - Sundi, S. A.

AU - Mohamed, S. B.

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AB - Inconel 718 known as hard-to-cut material due to its superior mechanical properties; high creep resistance, high fatigue strength, and able to withstand at elevated temperature which remains as challenge to possesses a lower surface roughness (Ra) during machining. The surface topology indicates the integrity of the machined parts. The quality of the Inconel 718 surface during end milling process was investigated. The experiments involved the use of PVD coated with TiAlN/ AlCrN ball nose tungsten carbide with varying of cutting speeds (Vc) ranging between 100 and 140 m/min, a feed rate (fz) of 0.1–0.2 mm/tooth, and an axial depth of cut (DoC) of 0.5–1.0 mm. The effects of the width of cut (WoC) between 0.2 and 1.8 mm were carried out. Due to the profile of the milled surface is complex; some variations in gap distance on the spiral profile were detected. The cutting path area to be found that, the new cut is overlapped which generate a new surface roughness by eliminating the previous cut thus the non-uniform feed marks being created on the machined surface. The surface roughness measured in feed direction was found to be lowered than pick a direction. Furthermore it was found that the WoC are causes the variation in Ra. During machining at low feed rates, the phenomenon of carbide particles was observed which results third body abrasion of machined surface. The particles are then trapped between the fragments and tear surface of the workpiece, thus increases the surface roughness. Based on the interaction effect of WoC and fz, it can be concluded that the feed rate effects on the quality of machined surface whilst WoC controls Ra variation.

KW - Ball nose end milling

KW - High speed machining

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KW - Notch wear

KW - Surface topology

KW - Third body abrasion

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