Please use this identifier to cite or link to this item:
http://hdl.handle.net/11375/27444
Title: | Improving the Tool Performance by Using Soft Coatings During Machining of Inconel 718 |
Authors: | Montazeri, Saharnaz |
Advisor: | Veldhuis, Stephen. C |
Department: | Mechanical Engineering |
Keywords: | Difficult-to-cut materials;Inconel 718;Soft coating |
Publication Date: | 17-Dec-2020 |
Abstract: | Increasing tool life is a significant objective in production. Achieving this objective in a machining process poses a significant challenge, especially during cutting hard-to-cut materials such as superalloys, due to the severe tool chipping/failure at the beginning of the cut. Although numerous attempts have been carried out to improve tool performance and prolong tool life during the machining of difficult-to-cut materials over the past several years, researchers have not obtained sufficient control over sudden tool failure/chipping. The focus of this study is to prolong tool life and control tool chipping by developing an ultra-soft deposited layer on the cutting tool that can protect it during the machining of difficult-to-cut materials such as Inconel 718. In the current study, an ultra-soft layer of material is deposited on the tool through two different techniques; a typical physical vapor deposition (PVD) technique and a novel developed method called “pre-machining”. In the PVD method, the soft layer is deposited under a high vacuum environment using a PVD coater. In the novel pre-machining method, the soft layer is deposited through a very short machining process involving Al-Si. It should be mentioned that soft coatings have never been used before for machining applications of difficult-to-cut materials including Inconel 718. This study shows that in contrast to what is expected, depositing an ultra-soft layer on the cutting tool significantly improves tool performance, by reducing chipping, and improving the machined surface integrity during cutting of Inconel 718. The obtained results show up to a 500% ± 10% improvement in tool life and around a 150% ± 10% reduction in cutting forces. Significant reductions in work hardening, residual stress, and surface roughness on the machined surface were other main achievements of the current study. |
URI: | http://hdl.handle.net/11375/27444 |
Appears in Collections: | Open Access Dissertations and Theses |
Files in This Item:
File | Description | Size | Format | |
---|---|---|---|---|
Montazeri_Saharnaz_202010_PhD.pdf | 10.77 MB | Adobe PDF | View/Open |
Items in MacSphere are protected by copyright, with all rights reserved, unless otherwise indicated.