Dynamic Chip Breaker Design for Nickel-Base, Inconel 718, Alloy with Coated Carbide Tools Using Negative Angle Tool Holder


Karabulut S., GÜLLÜ A.

MECHATRONIC SYSTEMS AND MATERIALS III, pp.758-763, 2009 (Journal Indexed in SCI) identifier

  • Publication Type: Article / Article
  • Volume:
  • Publication Date: 2009
  • Title of Journal : MECHATRONIC SYSTEMS AND MATERIALS III
  • Page Numbers: pp.758-763
  • Keywords: super alloy, Inconel 718, chip breaker, dynamic chip breaker, surface roughness, cutting insert temperature

Abstract

This study has focused on the chip-breaker design and experimental cutting of Inconel 718with the designed chip breaker. The process of chip breakage for Inconel 718 with respect to cutting speed, depth of cut and feed rate then chips and machined surfaces were analyzed from the experimental results. For this purpose, the nickel-base super alloy, Inconel 718was machined with a two layers PVD coated (TiAIN-TiN) carbide insert at feed rates of 0.10, 0.15, 0.20, 0.30 mm/rev, 0.5, 1, 1.5, 2 mm with depth of cuts, and 30, 45, 60, 75m/min cutting speeds using developed dynamic chip breaker with Negative tool holders in dry cutting conditions. Chip pictures and surface roughness (Ra) were recorded. Chip breakability during machining of the Inconel 718 depends on DC motor speed and chip breaker position on the cutting tool. The experimental results show that the designed chip breaker can break long chips at any cutting condition and acceptable surface finish can be achieved. In addition to this, according to cutting conditions, the usage of dynamic chip breaker on the surface of cutting insert is measured between 1% and 40% cooling effects using negative tool holder.