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Research Papers: Friction and Wear

Effect of Cutting Speed on Chipping and Wear of the SiAlON Ceramic Tool in Dry Finish Turning of the Precipitation Hardenable IN100 Aerospace Superalloy

[+] Author and Article Information
Mohamed A. Shalaby

Faculty of Engineering,
Department of Mechanical Engineering,
McMaster University,
Hamilton, ON L8S 4L7, Canada;
Department of Mechanical
Design and Production,
Technical Research Center,
Cairo 11461, Egypt
e-mails: shalabym@mcmaster.ca;
mohamedsmmri@gmail.com

Stephen C. Veldhuis

Faculty of Engineering,
Department of Mechanical Engineering,
McMaster University,
Hamilton, ON L8S 4L7, Canada
e-mail: veldhu@mcmaster.ca

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received May 28, 2018; final manuscript received July 27, 2018; published online October 11, 2018. Assoc. Editor: Xiaolei Wang.

J. Tribol 141(2), 021604 (Oct 11, 2018) (14 pages) Paper No: TRIB-18-1214; doi: 10.1115/1.4041072 History: Received May 28, 2018; Revised July 27, 2018

Inconel 100 (IN100) aerospace superalloy is used in manufacturing aero-engine components that operate at intermediate temperatures. It is considered to be a hard-to-cut material. Chipping of the tool edge is one of the major failure mechanisms of ceramic tools in finish cutting of superalloys, which causes a sudden breakage of the cutting edge during machining. Cutting temperature significantly depends on cutting speed. Varying the cutting speed will affect the frictional action during the machining operations. However, proper selection of the cutting variables, especially the cutting speed, can prevent chipping occurrence. In this work, the influence of controlling the cutting speed on the chipping formation in dry finish turning of IN100 aerospace superalloy using SiAlON ceramic tool has been investigated. Scanning electron microscope (SEM)/energy dispersing spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS), and three-dimensional wear measurements were used to make the investigations of the worn tool edges. It was found that variations of the cutting speeds in a certain range resulted in the generation of different lubricious and protective tribo-films. The presence of these tribo-films at the cutting region proved essential to prevent chipping of the cutting tool edge and to improve its wear resistance during finish turning of age-hardened IN 100 using SiAlON ceramic tools. Chip compression ratio and calculated values of the coefficient of friction at the tool–chip interface confirmed these results.

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Figures

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Fig. 1

Wear curves of SiAlON ceramic tool in finish dry turning of the hardened IN100 superalloy at cutting speeds of 100, 125, and 150 m/min

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Fig. 2

Scanning electron microscope (SEM) micrograph and energy dispersing spectroscopy (EDS) analysis of the worn SiAlON ceramic tool in finish dry turning of the hardened IN100 superalloy at cutting speed of 100 m/min

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Fig. 3

SEM micrograph and EDS analysis of the worn SiAlON ceramic tool in finish dry turning of the hardened IN100 superalloy at cutting speed of 125 m/min

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Fig. 4

SEM micrograph and EDS analysis of the worn SiAlON ceramic tool in finish dry turning of the hardened IN100 superalloy at cutting speed of 150 m/min

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Fig. 5

EDS elemental mapping of the worn SiAlON ceramic tool in finish dry turning of the hardened IN100 superalloy at cutting speed of 150 m/min

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Fig. 6

3D wear measurement of the worn SiAlON ceramic tool at different cutting speeds presenting the volume of valleys below the references: (a) at 100 m/min = 17.5 × 106μm3, (b) at 125 m/min = 3.5 × 106μm3, and (c) at 150 m/min = 9.5 × 106μm3

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Fig. 7

Chip compression ratio and chips undersides produced during the running-in period at different cutting speeds: (a)100 m/min, (b) 125 m/min, and (c) 150 m/min

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Fig. 8

EDS elemental mapping of the chip underside produced at cutting speed of 150 m/min in IN100 machining

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Fig. 9

Effect of cutting speed on cutting temperature in IN100 machining using SiAlON ceramic tool

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Fig. 10

Effect of cutting speed on cutting force components in IN100 machining using SiAlON ceramic tool

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Fig. 11

Effect of cutting speed on the coefficient of friction at the tool–chip interface in IN100 machining using SiAlON ceramic tool

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Fig. 12

XPS analysis of the worn SiAlON ceramic tool in machining IN100 superalloy at cutting speed of 100 m/min, during the running-in period

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Fig. 13

XPS analysis of the worn SiAlON ceramic tool in machining IN100 superalloy at cutting speed of 125 m/min, during the running-in period

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Fig. 14

XPS analysis of the worn SiAlON ceramic tool in machining IN100 superalloy at cutting speed of 150 m/min, during the running-in period

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Fig. 15

XPS analysis of chip underside in IN100 machining at 150 m/min

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Fig. 16

Wear curves of SiAlON ceramic tool in finish dry turning of the hardened IN100 superalloy at (150–125) m/min

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