A detailed investigation of residual stresses after milling Inconel 718 using typical production parameters for assessment of affected depth

• Production of superalloy gas turbine parts involves time consuming milling operations typically performed in a sequence from rough to finish milling. Rough milling using ceramic inserts allows high removal rates but causes severe sub-surface impact. A relatively large allowance is therefore left for subsequent cemented carbide milling. With increased knowledge of the affected depth it will be possible to reduce the machining allowance and increase efficiency of the manufacturing process. Milling Inconel 718 using typical production parameters has been investigated using new and worn ceramic and cemented carbide inserts. Residual stresses in a milled slot were measured by x-ray diffraction. Stresses were measured laterally across the slot and below the surface, to study the depth affected by milling. The most important result from this work is the development of a framework concerning how to evaluate the affected depth for a milling operation. The evaluation of a single milled slot shows great potential for determining the optimum allowance for machining. Our results show that the residual stresses are greatly affected by the ceramic and cemented carbide milling; both regarding depth as well as distribution across the milled slot. It has been shown that it is important to consider that the stresses across a milled slot are the highest in the center of the slot and gradually decrease toward the edges. Different inserts, ceramic and cemented carbide, and tool wear, alter how the stresses are distributed across the slot and the affected depth.

Ämnesord

TEKNIK OCH TEKNOLOGIER  -- Materialteknik -- Bearbetnings-, yt- och fogningsteknik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Materials Engineering -- Manufacturing, Surface and Joining Technology (hsv//eng)

Nyckelord

Allowance determination

Alloy 718

High speed milling

Material removal rate

Residual stresses

Surface integrity

Carbide cutting tools

Carbide tools

Carbides

Milling (machining)

Cutting tools

Production Technology

Manufacturing and materials engineering

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