PSI - Issue 53

10

A. Teixeira et al. / Procedia Structural Integrity 53 (2024) 352–366 Author name / Structural Integrity Procedia 00 (2019) 000–000

361

Fig. 13. Rake face images of the cutting tools for different cutting parameters: (a) v c =50 m/min and f=0.1 mm/rev; (b) v c =50 m/min and f=0.2 mm/rev; (c) v c =100 m/min and f=0.1 mm/rev; (d) v c =100 m/min and f=0.2 mm/rev; (e) v c =150 m/min and f=0.1 mm/rev; (f) v c =150 m/min and f=0.2 mm/rev. Wear evolution during turning has proven to be sensitive to feed parameter due to the significant notching and increased flank wear shown in all experiments done with a feed of 0.2 mm/rev, as seen in Fig. 14. This might be explained by Inconel 718 work hardening, which results in notch wear. This excessive notch wear at lower cutting speed led to an accelerated deterioration of the cutting edge and its ability to maintain strength properties culminating the premature failure of the tool. Additionally, higher feed rates cause more frequent contact between the tool and workpiece, which accelerates tool wear. The shorter intervals between contacts do not allow the tool sufficient time to cool down, accelerating wear (Wang & Liu, 2018).

Fig. 14. Crater and notch wear for feed value of 0.2 mm/rev at: (a) v c =50 m/min, (b) v c =100 m/min and (c) v c =150 m/min.

Regarding the tool wear mechanisms, mainly abrasion and material adhesion to the tools’ surface was observed, these are commonly reported in machining studies of this alloy (Pedroso et al., 2023; Sousa et al., 2023). These wear mechanisms were observed to be more intense when machining at the lowest cutting speed. Severe wear patterns were found such as notching and flank wear, at these speeds. These wear patterns affect the entire cutting edge, being more intense at the tool tip. The inserts sustained wear the chip breaker and far away from the tool tip, in the insert’s clearance face. This is caused by the chip formation and flow. The chip forms and curls onto the tools’ side, causing material adhesion on the surface, which can later cause adhesive wear. In Fig. 15, images depicting abrasive wear and material adhesion can be observed.