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Precision Milling of Nickel-Based Single-Crystal Superalloy by TiAlN Coated Small Diameter Solid Carbide End Mill


Affiliations
1 Indian Institute of Technology Bombay, Mumbai. Defence Metallurgical Research Laboratory, DRDO, Hyderabad, India
2 Defence Metallurgical Research Laboratory, DRDO, Hyderabad, India
3 Indian Institute of Technology Bombay, Mumbai, India
     

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Nickel-based superalloys pose cutting challenges due to their high strength, hot hardness, work hardening, and low thermal conductivity. Precision milling with small cutters is used for complex shapes and intricate profiles, but selecting appropriate machining parameters for these alloys is a challenging task. A set of machining conditions in slot milling with a TiAlN coated 1.5 mm diameter solid carbide end mills are investigated for dimensional accuracy, cutting forces, and specific energy. The dimensional accuracy in depth consists of within 10% of the depth of cut. The axial force and the feed force increase from 20 N to 106 N and from 17 N to 46 N, respectively with an increase in chip area from 0.8E-03 to 1.5E-03 mm 2 /rev. Tool rotation caused a gradual increase of cutting forces in up-milling and decreasing of cutting forces in down-milling. The specific energy increases from 393 to 865 J/mm 2 steeply under higher chip areas.

Keywords

Nickel-Based Single-Crystal Superalloy, Precision Milling, Solid Carbide End Mill, Cutting Forces, Specific Energy.
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  • Precision Milling of Nickel-Based Single-Crystal Superalloy by TiAlN Coated Small Diameter Solid Carbide End Mill

Abstract Views: 69  |  PDF Views: 1

Authors

Srinivasa Rao Nandam
Indian Institute of Technology Bombay, Mumbai. Defence Metallurgical Research Laboratory, DRDO, Hyderabad, India
A. Venugopal Rao
Defence Metallurgical Research Laboratory, DRDO, Hyderabad, India
Deepak Marla
Indian Institute of Technology Bombay, Mumbai, India
Amol A. Gokhale
Indian Institute of Technology Bombay, Mumbai, India
Suhas S. Joshi
Indian Institute of Technology Bombay, Mumbai, India

Abstract


Nickel-based superalloys pose cutting challenges due to their high strength, hot hardness, work hardening, and low thermal conductivity. Precision milling with small cutters is used for complex shapes and intricate profiles, but selecting appropriate machining parameters for these alloys is a challenging task. A set of machining conditions in slot milling with a TiAlN coated 1.5 mm diameter solid carbide end mills are investigated for dimensional accuracy, cutting forces, and specific energy. The dimensional accuracy in depth consists of within 10% of the depth of cut. The axial force and the feed force increase from 20 N to 106 N and from 17 N to 46 N, respectively with an increase in chip area from 0.8E-03 to 1.5E-03 mm 2 /rev. Tool rotation caused a gradual increase of cutting forces in up-milling and decreasing of cutting forces in down-milling. The specific energy increases from 393 to 865 J/mm 2 steeply under higher chip areas.

Keywords


Nickel-Based Single-Crystal Superalloy, Precision Milling, Solid Carbide End Mill, Cutting Forces, Specific Energy.

References