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DOI 10.1007/s00170-014-6115-x
ORIGINAL ARTICLE
Received: 12 January 2014 / Accepted: 26 June 2014 / Published online: 15 July 2014
# Springer-Verlag London 2014
1 Introduction
Nickel-based alloy Inconel 718 has outstanding mechanical
properties such as high oxidation resistance, corrosion resistance even at very high temperature, and retaining a high
mechanical strength under these conditions as well, with
which Inconel 718 has been widely used for many applications: aircraft gas turbines, reciprocating engines, metal processing (e.g., hot work tools and dies), space vehicles (e.g.,
aerodynamically heated skins, rocket engine parts), heat
treating equipments, nuclear power plants, chemical and petrochemical industries, and heat exchangers [1, 2]. Although
Inconel 718 is the most common nickel superalloy used in the
aerospace industry, some drawbacks are noticed, and within
these, the poor machinability is probably the worst [2]. As the
peculiar characteristics such as lower thermal conductivity,
work hardening, presence of abrasive carbide particles, hardness, affinity to react with tool material, etc., the cutting tools
wear very rapidly due to the high cutting temperature and high
cutting force. So, Inconel 718 is classified as difficult-toprocess materials [3]. Therefore, all the cutting parameters,
such as tool and coating material choice, tool geometry, machining strategy, cutting speed, feed rate, depth of cut, lubrication, etc., must be controlled and selected in order to achieve
a correct surface integrity and an acceptable tool life for the
machined parts [4, 5].
270
Content
Si
Mn
Ni
Cr
Ti
Composition (wt%)
Content
Composition (wt%)
0.037
Nb+Ta
5.12
0.12
Mo
2.99
0.06
Al
0.51
0.0007
B
0.0025
0.0042
Cu
0.02
52.17
Co
<0.1
19.72
Fe
Last
0.87
271
Workpiece
material
Tensile
strength (MPa)
Yield strength
(MPa)
Elongation
(%)
Hardness
(HRC)
Cutting tool
Blade length
(mm)
Fillet radius
(mm)
Helical
angle ()
Rake
angle ()
Inconel 718
1,447
1,207
22
42
30
10
machine tool vibration that is deadly for the high-speed milling of Inconel 718. When processing the Inconel 718 parts
with curved surface, the change of cutting force in high-speed
milling should be smooth as far as possible. Though decreasing the feed rate at the certain section can smooth out the force
peaks, regrettably, no available method combined with the
high spindle speed is proposed in decreasing the fluctuations
of cutting force while the spindle speed is the most important
characteristic for the high-speed milling.
The machining parameter optimization of high-speed milling for the Inconel 718 curved surface is closely related with
the cutting force, while the spindle speed is the most important
characteristic for the high-speed milling. In this paper, the
relationship between the spindle speed and the cutting force
in the high-speed milling process of Inconel 718 curved
surface is studied. Then, with the small fluctuation of cutting
force as constraint condition, the optimum spindle speed range
in the high-speed milling of Inconel 718 curved surface is
selected, and the feed per tooth and the cutting depth are
analyzed based on the cutting force as well. These studies
are of great significance for improving machining quality and
machining efficiency for the Inconel 718 parts with curved
surface.
2 Experiment details
2.1 Workpiece material
The workpiece used in this study is Inconel 718 sheet material
with the size of 505030 mm. Its chemical composition
and mechanical properties are shown in Tables 1 and 2,
respectively.
Values
Fig. 1 Coated carbide ball end cutter
500450350 40
10
272
surface, the machining parameter optimization in highspeed milling of Inconel 718 curved surface based on
cutting force is carried out.
273
The noises in the cutting force signals are usually highfrequency signals, so the LEP (low-pass filter) method based
on FFT is used for the preprocessing of the cutting force
274
jy 0j
3=2 . In addition, the movement direction
1y0 2
of spindle when the cutting tool passes the point is also
introduced for the analysis of the cutting forces. The curvature
of the point (COP, for short), the concavity or convexity of the
point (COCOP, for short), and the movement direction of
formula of K
spindle (MDOS, for short) for the seven points are shown in
Table 5.
Based on the obtained cutting force components for the
seven points, the resultant force can be calculated based on the
three cutting force components Fx, Fy, and Fz, just the square
root of the sum of the squares for the three cutting force
components,
so
the
resultant
force
is
p
2
2
2
F Fx Fy Fz . Then, the resultant force is used
for analyzing.
As shown in Table 5, the COP and COCOP are the same
for two groups of points: (1) point 1 and point 3 and (2) point 5
and point 7, but the MDOS is different. The diagram of
resultant forces for point 1 and point 3 changing in relation
to the spindle speed is shown in Fig. 7, and the diagram of
resultant forces for point 5 and point 7 changing in relation to
the spindle speed is shown in Fig. 8. It can be obviously found
that with the increase of the spindle speed, the change law of
the cutting force is the same for point 1 and point 3 and for
point 5 and point 7. However, the cutting force of point 1 is
larger than that of point 3, and the cutting force of point 5 is
larger than that of point 7. So, the MDOS affects the cutting
force in high-speed milling of Inconel 718 curved surface, and
the cutting force is larger when the movement direction of
spindle is in Z direction.
For another two groups of points, (1) point 1 and point 2
and (2) point 5 and point 6, the COCOP and the MDOS are the
Point
COP
COCOP
MDOS
Point 1
Point 2
Point 3
Point 4
Point 5
Point 6
Point 7
K1 =0.035
K2 =0.058
K3 =0.035
K4 =0
K5 =0.035
K6 =0.058
K7 =0.035
Convexity
Convexity
Convexity
Inflection point
Concavity
Concavity
Concavity
+Z
+Z
Z
Z
Z
Z
+Z
275
276
4 Conclusions
Nickel-based alloy Inconel 718 is a kind of typical difficult-toprocess material, and few researches are reported about the
machining parameter optimization in high-speed milling of
Inconel 718 parts with curved surface at present. Nowadays, it
is still essential and irreplaceable to study the machining
parameter optimization through experimental method. This
paper presented the machining parameter optimization in
high-speed milling of Inconel 718 curved surface based on
cutting force.
The experimental study is carried out with the spindle
speed n=2,000~10,000 rpm (increasing by 500 rpm), the feed
per tooth fz =0.005~0.035 mm/z (increasing by 0.05 mm/z),
and the cutting depth ap = 0.05 ~ 0.4 mm (increasing by
0.05 mm). The experiment results show that:
277
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
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