ABSTRACT

The demand for high temperature-resistant superalloys such as Inconel 718 is increasing rapidly, as they possess superior mechanical, chemical, and physical properties. Hence, these materials are highly adaptable for aerospace, nuclear, and marine applications. Nonetheless, during machining of such alloys, high temperatures develop at the interface region. It accelerates the tool wear and adversely affects the integrity of the prepared surfaces. Although conventional metalworking fluids are competent in normalizing/limiting the cutting-edge temperature, the environmental obligations and health issues to the workers have forced the manufacturing industry to move towards environment-friendly machining process, viz. dry machining. High-speed machining of Inconel 718 (under dry condition) can lead to the attainment of high cutting temperatures, thereby activating the mechanisms of built-up-edge (BUE) development and diffusion, leading to enhanced wear rate of tool. Besides, high temperatures can alter the integrity, infuse residual stresses, and promote crack generation/propagation on the processed surface. Therefore, the present paper contributes a detailed insight into heat generation during machining of Inconel 718 and its influence on various machining responses. Additionally, the work addresses multiple possibilities to reduce the cutting temperature with due emphasis on distinct machining methodologies, viz. dry, wet, and tool texturing.

Abbreviations: BUE: Built-up Edge; AISI: American Iron and Steel Institute; AJM: Abrasive Jet Machining; AlTiN: Aluminium Titanium Nitride; Al₂O₃: Aluminum Oxide or Alumina; Al₂O₃/SiC: SiC whisker-reinforced alumina Al₂O₃ ceramic; Al₂O₃-TiC: TiC added alumina ceramic; AS: Conventional tool; AT-PA: Parallel grooves; AT-PE: Perpendicular grooves; AT-W: Wavy pattern; CaF₂: Calcium fluoride; CBN: Cubic boron nitride; CBN-OR: Perpendicular to cutting edge; CBN-ORE : Perpendicular grooves 30 µm away from main cutting edge; CBN-PA: Parallel to cutting edge; CFT: Nano textured tool; CFT WS: Nano textured with soft coated WS₂; CrN: Chromium Nitride; CT: Conventional cutting tool; DOC notch wear: Depth-of-cut notch wear; EBSD: Electron back scatter diffraction; ECM: Electrochemical machining; FCC: Face centered cubic; GWP: Global warming potential; HPC: High-pressure cooling; HPJ: High-pressure jet; HPJA: High-pressure jet assistance; HRSA: Heat-resisted super alloy; HSS: High-speed steel; IPF: Inverse pole figure; ISO: International organization for standardization; l/h: liter/hour; L/min: Liter/minute; Micro-EDM: Micro-electrical machining; MoS₂: Molybdenum disulfide; MQL: Minimum quantity lubrication; MWFs: Metal-working fluids; NIOSH: National Institute of Occupational Safety and Health; PCBN: Polycrystalline Cubic Boron Nitride; PVD: Physical vapor deposition; SEM: Scanning electron microscope; Si₃N₄: Silicon nitride; ST: Graphite soft-coated tool; STT-F: Linear grooves on the flank surface; STT-R: Elliptical textures on the rake face; STT-0: Plain WC/Co carbide tool; STT-1: Elliptical grooves; STT-2: Parallel grooves; STT-3: Perpendicular grooves; TiAlN: Titanium Aluminium Nitride; TiCN: Titanium Carbonitride; TiN: Titanium Nitride; T-IPA: Perpendicular textures to chip flow; T-IPE: Parallel textures to the chip flow; T-PA: Texture surfaces inclined an angle to the chip flow; TT: Textured tool under dry condition; TT+SL: Textured tool under solid lubricant-assisted MQL cooling conditions; T1: Un-textured tool; T2: Texture tool having circular pit holes; T3: Hybrid texture tool combination of circular pit holes and linear grooves; TT: Textured inserts; TT: WS₂-soft-coated WS₂ textured tool; T1: Conventional insert; T2: Conical dimple-textured tool; T3: Square dimple-shaped insert; T4: Scratches provided on the cutting insert; T-1: Untextured insert; T-2: Pit holes textured insert; T-3: Hybrid textured insert; US: United States; USM: Ultrasonic Machining; WC: Tungsten carbide; WC–Co: Tungsten carbide-cobalt; WEDM: Wire electrical discharge machining; WS₂: Tungsten disulfide

摘要

由于Inconel 718等具有优异的机械，化学和物理性能，因此对耐高温超级合金的需求正在迅速增长。因此，这些材料高度适用于航空，核和海洋应用。然而，在加工此类合金的过程中，在界面区域仍会产生高温。它会加速工具磨损，并对准备好的表面的完整性产生不利影响。尽管常规的金属加工液能够胜任/限制尖端温度，但是对工人的环境义务和健康问题迫使制造行业朝着环境友好的机械加工方向发展。干式加工。Inconel 718的高速加工（在干燥条件下）可导致达到较高的切削温度，从而激活积屑瘤（BUE）形成和扩散的机制，从而提高了工具的磨损率。此外，高温会改变完整性，注入残余应力并促进在加工表面上产生裂纹/扩展裂纹。因此，本文对Inconel 718加工过程中的热量产生及其对各种加工响应的影响做出了详细的了解。此外，这项工作还提出了多种降低切削温度的可能性，并适当强调了不同的加工方法。干，湿和工具纹理化。并促进在加工表面上裂纹的产生/传播。因此，本文对Inconel 718加工过程中的热量产生及其对各种加工响应的影响做出了详细的了解。此外，这项工作还提出了多种降低切削温度的可能性，并适当强调了不同的加工方法。干，湿和工具纹理化。并促进在加工表面上裂纹的产生/传播。因此，本文对Inconel 718加工过程中的热量产生及其对各种加工响应的影响做出了详细的了解。此外，这项工作还提出了多种降低切削温度的可能性，并适当强调了不同的加工方法。干，湿和工具纹理化。

缩写： BUE：内置边缘；AISI：美国钢铁协会；AJM：磨料喷射加工；AlTiN：氮化铝钛；Al ₂ O ₃：氧化铝或氧化铝；Al ₂ O ₃ / SiC：SiC晶须增强氧化铝Al ₂ O ₃陶瓷；Al ₂ O ₃ -TiC：添加了TiC的氧化铝陶瓷；AS：常规工具；AT-PA：平行凹槽；AT-PE：垂直凹槽；AT-W：波浪状图案；氟化钙₂：氟化钙; CBN：立方氮化硼；CBN-OR：垂直于切削刃；CBN-ORE：与主切削刃相距30 µm的垂直凹槽；CBN-PA：与切削刃平行；CFT：纳米纹理工具；CFT WS：纳米纹理，软涂层WS ₂；CrN：氮化铬；CT：常规切削工具；DOC缺口磨损：切深缺口磨损；EBSD：电子背散射衍射；ECM：电化学加工；FCC：面心立方；全球升温潜能值：全球变暖的潜力；HPC：高压冷却；HPJ：高压射流；HPJA：高压喷射辅助；HRSA：耐热超级合金；HSS：高速钢；IPF：反极图；ISO：国际标准化组织；l / h：升/小时；L / min：升/分钟；Micro-EDM：微电加工；硫化钼₂：二硫化钼；MQL：最小量润滑；MWF：金属加工液；NIOSH：国家职业安全与健康研究所；PCBN：多晶立方氮化硼；PVD：物理气相沉积；SEM：扫描电子显微镜；硅₃ N ₄：氮化硅；ST：石墨软涂层工具；STT-F：侧面上的线性凹槽；STT-R：前刀面上的椭圆形纹理；STT-0：普通WC / Co硬质合金刀具；STT-1：椭圆形凹槽；STT-2：平行凹槽；STT-3：垂直凹槽；TiAlN：氮化铝钛；TiCN：碳氮化钛；TiN：氮化钛；T-IPA：垂直于切屑流的纹理；T-IPE：与切屑流平行的纹理；T-PA：纹理表面与切屑流成一定角度；TT：干燥条件下的纹理工具；TT + SL：在固体润滑剂辅助的MQL冷却条件下的纹理化工具；T1：无纹理的工具；T2：具有圆形凹坑的纹理工具；T3：圆形凹坑孔和线性凹槽的混合纹理工具组合；TT：质感刀片；TT：WS _2-软涂层的WS ₂纹理工具；T1：常规刀片；T2：锥形酒窝纹理工具；T3：方形酒窝形刀片；T4：切削刀片上有划痕；T-1：无纹理的插入物；T-2：坑纹纹理的刀片；T-3：混合纹理插入物；美国：美国；USM：超声波加工；WC：碳化钨；WC-Co：碳化钨-钴；WEDM：电火花线切割加工；WS ₂：二硫化钨