PSI - Issue 53

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

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Fig. 21. Wear on the rake face at v c =150 m/min and f=0.2 mm/rev: (a) experimental and (b) simulation.

5. Conclusions After the conduction of this work the following conclusions can be drawn:  Machining parameter influence on the generated cutting forces were assessed, with the highest cutting force value being obtained for lower cutting speeds and higher feed rates, with recorded values ranging from 144-78 N and 213-149 N at f= 0.1 and f=0.2 mm/rev, respectively;  With an increase in cutting speed, the registered force values tended to decrease, with the maximum cutting force value being registered for a condition of vc =50 m/min. This was also the condition in which the registered tool wear was higher, with the tools manifesting excessive flank and crater wear;  Regarding the measured surface roughness values, the highest value was registered for higher feed rates (above 3 µ m), while for lower feed rates the registered values were around 0.8 µ m;  As mentioned, with an increase in cutting speed, there was a tendency for the cutting force values to be lower, this can be attributed to thermal softening of the workpiece. A decrease of about 46% was registered, from 50 m/min to 150 m/min, for the condition of f = 0.1 mm/rev. A similar decrease, of about 30% was registered for f = 0.2 mm/rev;  Cutting forces obtained from the numerical models correlated well with the experimental values, with errors lower than 3%, except for one cutting condition, with the lowest value of cutting speed. This can be attributed to the excessive tool-wear sustained at these speeds, thus causing an increase of the cutting forces;  Although it was not possible to predict flank wear, the numerical model was able to accurately predict tool wear distribution on the tools’ rake faces. Acknowledgements Authors gratefully acknowledge the funding of Project Hi-rEV – Recuperação do Setor de Componentes Automóveis (C644864375-00000002) cofinanced by Plano de Recuperação e Resiliência (PRR), República Portuguesa through NextGeneration EU. References Agmell, M., Bushlya, V., M’Saoubi, R., Gutnichenko, O., Zaporozhets, O., Laakso, S. V., & Ståhl, J.-E. (2020). Investigation of mechanical and thermal loads in pcBN tooling during machining of Inconel 718. The International Journal of Advanced Manufacturing Technology , 107 (3–4), 1451–1462. https://doi.org/10.1007/s00170-020-05081-8 Arrazola, P. J., Garay, A., Fernandez, E., & Ostolaza, K. (2014). Correlation between tool flank wear, force signals and surface integrity when turning bars of Inconel 718 in finishing conditions. International Journal of Machining and Machinability of Materials , 15 (1/2), 84. https://doi.org/10.1504/IJMMM.2014.059193 Aspinwall, D. K., Dewes, R. C., Ng, E.-G., Sage, C., & Soo, S. L. (2007). The influence of cutter orientation and workpiece angle on machinability when high-speed milling Inconel 718 under finishing conditions. International Journal of Machine Tools and Manufacture , 47 (12–13), 1839–1846. https://doi.org/10.1016/j.ijmachtools.2007.04.007 Buddaraju, K. M., Ravi Kiran Sastry, G., & Kosaraju, S. (2021). A review on turning of Inconel alloys. Materials Today: Proceedings , 44 , 2645– 2652. https://doi.org/10.1016/j.matpr.2020.12.673 Cantero, J., Díaz-Álvarez, J., Infante-García, D., Rodríguez, M., & Criado, V. (2018). High Speed Finish Turning of Inconel 718 Using PCBN