Evaluation of surface integrity in micro drilling process for nickel-based superalloy

International Journal of Advanced Manufacturing Technology

Volumn 55, Issue 5-8, 2011, Pages 465-476

  Imran, Muhammad ^a   Mativenga, Paul T ^a   Gholinia, Ali ^a   Withers, Philip J ^a  

^a UNIVERSITY OF MANCHESTER   (United Kingdom)

Author keywords

Micro drilling; Nickel alloy; Surface and subsurface deformation; Surface integrity

Indexed keywords

BACKSCATTER ELECTRON MICROSCOPY; CRYSTAL MISORIENTATION; CUTTING CONDITIONS; DEFORMED SUBSURFACE LAYERS; ELECTRON BACK SCATTER DIFFRACTION; HIGH ASPECT RATIO; INCONEL 718 ALLOY; LARGE-SCALE DEFORMATION; MECHANICAL DRILLING; METALLURGICAL CHARACTERIZATION; MICRO DRILLING; MICRO HOLES; MODIFIED SURFACES; NANOSTRUCTURED SURFACE LAYER; NICKEL- BASED SUPERALLOYS; PARENT METAL; SUBSURFACE LAYER; SUBSURFACE REGIONS; SURFACE INTEGRITY; THERMO-MECHANICAL LOADING; WET CUTTING;

ASPECT RATIO; BACKSCATTERING; CRYSTAL MICROSTRUCTURE; DEFORMATION; GRAIN REFINEMENT; NANOINDENTATION; NICKEL ALLOYS; SUPERALLOYS; TRANSMISSION ELECTRON MICROSCOPY;

DRILLS;

EID: 79958784229     PISSN: 02683768     EISSN: 14333015     Source Type: Journal    
DOI: 10.1007/s00170-010-3062-z     Document Type: Article

References (49)

1. Smithberg D (1987) Inconel 718 machining manual. Report 6M59-559. Manufacturing Research and Development, Boeing Commercial Airplane Company.
2. Kreysa G, Schütze M (2008) DECHEMA corrosion handbook. DECHEMA revised and extended 2nd Edition. Dechema, Frankfurt
3. EO Ezugwu J Bonney Y Yamane 2003 An overview of the machinability of aeroengine alloys J Mater Process Technol 134 2 233 253 10.1016/S0924-0136(02) 01042-7
4. EO Ezugwu ZM Wang CI Okeke 1999 Tool life and surface integrity when machining Inconel 718 with PVD and CVD-coated tools Tribol Trans 42 2 353 360 10.1080/10402009908982228 (Pubitemid 29384924)
5. R Arunachalam 2000 Machinability of nickel-based high temperature alloys Mach Sci Technol 4 1 127 168 1921290 10.1080/10940340008945703 (Pubitemid 30589587)
6. IA Choudhury 1998 Machinability of nickel-base super alloys: a general review J Mater Process Technol 77 1 278 284 10.1016/S0924-0136(97)00429-9
7. R Komanduri TA Schroeder 1986 On shear instability in machining a nickel-iron base superalloy J Eng Ind Trans ASME 108 93 100 10.1115/1.3187056
8. YC Chen 2003 Study on wear mechanisms in drilling of Inconel 718 superalloy J Mater Process Technol 140 1 269 273 10.1016/S0924-0136(03)00792-1
9. T Kitagawa A Kubo K Maekawa 1997 Temperature and wear of cutting tools in high-speed machining of Inconel 718 and Ti-6Al-6 V-2Sn Wear 202 2 142 148 10.1016/S0043-1648(96)07255-9 (Pubitemid 27222678)
10. EA Ezugwu AR Machado IR Pashby J Wallbank 1991 Effect of high-pressure coolant supply when machining a heat-resistant nickel-based superalloy Lubr Eng 47 9 751 757 (Pubitemid 21720157)
11. BM Kramer 1987 On tool materials for high speed machining Trans. of ASME, Journal of Engineering for Industry 109 2 87 91 10.1115/1.3187113 (Pubitemid 17587166)
12. Griffiths BJ (2001) Manufacturing surface technology, surface integrity and functional performance. Manufacturing Engineering Modular Series Penton press, London
13. ANSI-B211.1 (1986) American national standards on surface integrity. American National Standards Institute, Washington, D.C
14. M Field 1974 Surface integrity can affect reliability of your high strength parts Mach Tool Blue Book 69 2 90 97 1511586
15. BJ Griffiths DC Furze 1987 Tribological advantages of white layers produced by machining J Tribol 109 2 338 342 10.1115/1.3261363 (Pubitemid 17569979)
16. M Field JF Kahles 1971 Review of surface integrity of machined components CIRP Ann 20 2 153 163
17. EO Ezugwu SH Tang 1995 Surface abuse when machining cast iron (G-17) and nickel-base superalloy (Inconel 718) with ceramic tools J Mater Process Technol 55 2 63 69 10.1016/0924-0136(95)01786-0
18. W Li PJ Withers D Axinte M Preuss P Andrews 2009 Residual stresses in face finish turning of high strength nickel-based superalloy J Mater Process Technol 209 10 4896 4902 10.1016/j.jmatprotec.2009.01.012
19. J Kwong DA Axinte PJ Withers MC Hardy 2009 Minor cutting edge-workpiece interactions in drilling of an advanced nickel-based superalloy Int J Mach Tools Manuf 49 7-8 645 658 10.1016/j.ijmachtools.2009.01.012
20. R M' Saobui JC Outerio H Chandrasekarn OW Dillon IS Jawahir 2008 A review of the surface integrity in machining and its impact on functional performance and life of machined products Int J Sustain Manuf 1 203 236
21. AB Sadat 1987 Surface characteristics of machined Inconel 718 nickel base superalloy using natural and controlled contact length tools Int J Mach Tools Manuf 27 3 333 342 10.1016/S0890-6955(87)80006-8
22. D Novovic RC Dewes DK Aspinwall W Voice P Bowen 2004 The effect of machined topography and integrity on fatigue life Int J Mach Tools Manuf 44 2-3 125 134 10.1016/j.ijmachtools.2003.10.018
23. M Field JF Kahles WP Koster 1966 The surface effects produced in nonconventional metal removal-comparison with conventional machining techniques Metal Engineering Quarterly 6 32 45
24. MM El-Khabeery SM Saleh MR Ramadan 1991 Some observations of surface integrity of deep drilling holes Wear 142 2 331 349 10.1016/0043-1648(91)90173-R
25. YK Chou CJ Evans 1999 White layers and thermal modeling of hard turned surfaces Int J Mach Tools Manuf 39 12 1863 1881 10.1016/S0890-6955(99)00036-X (Pubitemid 30508629)
26. YB Guo AW Warren 2005 Microscale mechanical behavior of the subsurface by finishing processes J Manuf Sci Eng 127 333 338 10.1115/1.1807853 (Pubitemid 40718388)
27. S Akcan S Shah SP Moylan PN Chhabra S Chandrasekar HTY Yang 2002 Formation of white layers in steels by machining and their characteristics Metall Mater Trans, A Phys Metall Mater Sci 33 4 1245 1254 10.1007/s11661-002- 0225-z (Pubitemid 34474969)
28. SP Moylan S Kompella S Chandrasekar TN Farris 2003 A new approach for studying mechanical properties of thin surface layers affected by manufacturing processes J Manuf Sci Eng 125 2 310 315 10.1115/1.1559161
29. R Li L Riester TR Watkins PJ Blau AJ Shih 2008 Metallurgical analysis and nanoindentation characterization of Ti-6Al-4 V workpiece and chips in high-throughput drilling Mater Sci Eng, A 472 1-2 115 124 (Pubitemid 350226992)
30. Warren AW, Guo YB (2004) An experimental study on subsurface mechanical behavior, residual stress, and microstructure induced by process dynamics in machining. American Society of Mechanical Engineers, Manufacturing Engineering Division 15:985-992
31. BJ Griffiths 1987 Mechanisms of white layer generation with reference to machining and deformation processes J Tribol 109 3 525 530 10.1115/1.3261495 (Pubitemid 17615967)
32. ARC Sharman A Amarashighe K Ridgway 2008 Tool life and surface integrity aspects when drilling and hole making in Inconel 718 J Mater Process Technol 200 1 424 432 10.1016/j.jmatprotec.2007.08.080 (Pubitemid 351318185)
33. J Kwong DA Axinte PJ Withers 2009 The sensitivity of Ni-based superalloy to hole making operations: influence of process parameters on subsurface damage and residual stress J Mater Process Technol 209 8 3968 3977 10.1016/j. jmatprotec.2008.09.014
34. JC Villegas LL Shaw 2009 Nanocrystallization process and mechanism in a nickel alloy subjected to surface severe plastic deformation Acta Mater 57 19 5782 5795 10.1016/j.actamat.2009.08.005
35. R M'Saoubi L Ryde 2005 Application of the EBSD technique for the characterisation of deformation zones in metal cutting Mater Sci Eng, A 405 1-2 339 349 (Pubitemid 41258321)
36. A Yamamoto T Yamada S Nakahigashi L Liu M Terasawa H Tsubakino 2004 Effects of surface grinding on hardness distribution and residual stress in low carbon austenitic stainless steel SUS316L ISIJ Int 44 10 1780 1782 10.2355/isijinternational.44.1780 (Pubitemid 40002143)
37. Field M, Koster WP (1968) Surface integrity in conventional machining-chip removal processes. American Society of Tool and Manufacturing Engineers-creative manufacturing seminars, technical papers EM68-5161-36
38. JG Li M Umemoto Y Todaka K Tsuchiya 2007 A microstructural investigation of the surface of a drilled hole in carbon steels Acta Mater 55 4 1397 1406 10.1016/j.actamat.2006.09.043 (Pubitemid 46176689)
39. SS Bosheh PT Mativenga 2006 White layer formation in hard turning of H13 tool steel at high cutting speeds using CBN tooling Int J Mach Tools Manuf 46 2 225 233 10.1016/j.ijmachtools.2005.04.009 (Pubitemid 41563986)
40. Field M, Kahles JF, Koster WP (1968) Surface integrity in machining and grinding. American Society of Tool and Manufacturing Engineers-creative manufacturing seminars, technical papers 21-21.
41. DA Axinte P Andrews 2007 Some considerations on tool wear and workpiece surface quality of holes finished by reaming or milling in a nickel base superalloy Proc Inst Mech Eng B J Eng Manuf 221 4 591 603 10.1243/09544054JEM704 (Pubitemid 46897851)
42. M Imran PT Mativenga S Kannan D Novovic 2008 An experimental investigation of deep-hole microdrilling capability for a nickel-based superalloy Proc Inst Mech Eng B J Eng Manuf 222 12 1589 1596 10.1243/09544054JEM1217
43. J Gu G Barber S Tung R-J Gu 1999 Tool life and wear mechanism of uncoated and coated milling inserts Wear 225 273 284 10.1016/S0043-1648(99)00074-5 (Pubitemid 30112875)
44. Shaw MC (2005) Metal cutting principles, 2nd edn. Oxford University Press, Inc, New York
45. Y Matsumoto MM Barash CR Liu 1986 Effect of hardness on the surface integrity of AISI 4340 steel J Eng Ind 108 3 169 175 10.1115/1.3187060 (Pubitemid 16640241)
46. MA Meyers A Mishra DJ Benson 2006 Mechanical properties of nanocrystalline materials Prog Mater Sci 51 4 427 556 10.1016/j.pmatsci.2005.08. 003 (Pubitemid 43204494)
47. MA Meyers YB Xu Q Xue MT Pérez-Prado TR McNelley 2003 Microstructural evolution in adiabatic shear localization in stainless steel Acta Mater 51 5 1307 1325 10.1016/S1359-6454(02)00526-8
48. R Komanduri 1982 Some clarifications on the mechanics of chip formation when machining titanium alloys Wear 76 1 15 34 10.1016/0043-1648(82)90113-2 (Pubitemid 12524371)
49. R Komanduri N Chandrasekaran LM Raff 2000 M.D. Simulation of nanometric cutting of single crystal aluminum-effect of crystal orientation and direction of cutting Wear 242 1-2 60 88 10.1016/S0043-1648(00)00389-6