Study on wear rate of TiAIN ball nose during milling inconel 718 under flooded lubrication

Muhammad Rafie Empari, Nurul Nadia (2015) Study on wear rate of TiAIN ball nose during milling inconel 718 under flooded lubrication. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Inconel 718 is a nickel-based alloy that is widely used in the aerospace industry and prominently known as a hard to machine material due to abrasiveness, high hardness and low thermal conductivity. These characteristics contribute to the changes in the shape of the cutting tool during machining Inconel 718 material which affects the wear rate of the cutting tool itself. To understand this situation, this research is conducted to meet the following objectives; to study the effect of machining parameters on the wear rate of ball nose TiAlN during end milling of Inconel 718 under flooded lubrication, to develop a mathematical model to predict the wear rate by using Response Surface Methodology (RSM) analysis and to determine optimum process parameters to minimize the wear rate of ball nose TiAlN during end milling of Inconel 718 under flooded lubrication. RSM through Box-Behnken was used to analyze the relationship between the input and output specifications. A total of 17 experiments was conducted. The machining parameters were cutting speed,Vc, (100 m/min to 140 m/min), feed rate,fz, (0.1 mm/tooth to 0.2 mm/tooth) and depth of cut,ap, (0.5 mm to 1.0 mm). Meanwhile, width of cut was set as a fixed parameter at 1.0 mm. In this research, TiAlN ball nose of diameter 10 mm was tested due to its hardness which increases by 40% compared to uncoated tool. During machining operation, flank wears VB1 and notch wear VB3 were measured by using tools maker microscope. Based on the results, it showed that the cutting speed affects the rapid wear rate. It was found that as the cutting speed increase, the wear rate will increase. Meanwhile, ap and fz affect also significantly affect the wear rate of the tool. Besides, a mathematical model to predict the wear rate was developed. Lastly, the optimum parameter was determined which the Vc (100 m/min), fz (0.10 mm/tooth) and ap (0.81 mm). The error between predicted wear rate using this model and actual wear rate was only 2.21%.

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