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<p>Nickel-based superalloys like Inconel 718 are challenging to machine due to their high mechanical strength, low thermal conductivity, work hardening tendencies, creep resistance, among others. These characteristics result in elevated cutting temperatures and forces, which accelerate tool wear. Thus, selecting the appropriate lubri-cooling methods and cutting parameters is crucial for extending tool life and improving machining efficiency. In this sense, this study evaluates the tool life and wear mechanisms in the milling of Inconel 718 using five lubri-cooling techniques: dry machining (DM), compressed air (CA), minimum quantity lubrication (MQL), vortex tube (VT), and flood cooling (FC). Two cutting speed levels and two feed per tooth levels were studied for each cooling condition. Tool life was assessed by measuring flank wear, and wear mechanisms were analyzed using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). The primary wear mechanisms observed adhesive and abrasive wear, as well as mechanical chipping, depending on the cutting conditions. The results indicated that the flood method (FC) provided the longest tool life, whereas dry machining (DM) led to the shortest tool life due to excessive heat generation and lack of cooling. Air-cooled methods (MQL, CA, and VT) exhibited intermediate performance, with no significant difference among them. Increasing cutting speed significantly reduced tool life, primarily due to higher cutting temperatures. No thermal cracking was observed in any of the lubri-cooling methods, including flood cooling, suggesting effective thermal management. Overall, the flood cooling method was found to be the most effective in minimizing wear and enhancing tool life during Inconel 718 milling.</p>

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Tool life and wear mechanisms in the milling of inconel 718 under different cooling strategies

  • 期刊论文

  • 发表日期：

    2025年10月23日

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  • Lucas Melo Queiroz Barbosa,
  • Pedro Henrique Pires França,
  • Gustavo Henrique Nazareno Fernandes,
  • Leonardo Rosa Ribeiro da Silva,
  • Paulo Sérgio Martins,
  • Álisson Rocha Machado

摘要

Nickel-based superalloys like Inconel 718 are challenging to machine due to their high mechanical strength, low thermal conductivity, work hardening tendencies, creep resistance, among others. These characteristics result in elevated cutting temperatures and forces, which accelerate tool wear. Thus, selecting the appropriate lubri-cooling methods and cutting parameters is crucial for extending tool life and improving machining efficiency. In this sense, this study evaluates the tool life and wear mechanisms in the milling of Inconel 718 using five lubri-cooling techniques: dry machining (DM), compressed air (CA), minimum quantity lubrication (MQL), vortex tube (VT), and flood cooling (FC). Two cutting speed levels and two feed per tooth levels were studied for each cooling condition. Tool life was assessed by measuring flank wear, and wear mechanisms were analyzed using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). The primary wear mechanisms observed adhesive and abrasive wear, as well as mechanical chipping, depending on the cutting conditions. The results indicated that the flood method (FC) provided the longest tool life, whereas dry machining (DM) led to the shortest tool life due to excessive heat generation and lack of cooling. Air-cooled methods (MQL, CA, and VT) exhibited intermediate performance, with no significant difference among them. Increasing cutting speed significantly reduced tool life, primarily due to higher cutting temperatures. No thermal cracking was observed in any of the lubri-cooling methods, including flood cooling, suggesting effective thermal management. Overall, the flood cooling method was found to be the most effective in minimizing wear and enhancing tool life during Inconel 718 milling.