Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy
This paper is devoted to the problem of wear resistance in square Si3N4 ceramic cutting inserts, which exhibit high hardness and strength, in combination with brittleness, and are subject to increased mechanical and thermal loads in machining super alloys for aviation purposes (e.g., a nickel-based...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-07-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/13/7/1241 |
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| author | Marina A. Volosova Anna A. Okunkova Khaled Hamdy Alexander P. Malakhinsky Khasan I. Gkhashim |
| author_facet | Marina A. Volosova Anna A. Okunkova Khaled Hamdy Alexander P. Malakhinsky Khasan I. Gkhashim |
| author_sort | Marina A. Volosova |
| collection | DOAJ |
| description | This paper is devoted to the problem of wear resistance in square Si3N4 ceramic cutting inserts, which exhibit high hardness and strength, in combination with brittleness, and are subject to increased mechanical and thermal loads in machining super alloys for aviation purposes (e.g., a nickel-based alloy of Inconel 718 type). Microtextures were proposed to reduce the intensity of the contact loads on the pad between the cutting edge and the workpiece. The simulation of the mechanical and thermal loads demonstrated the superior ability of the faces with the preformed microgrooves (125 µm in width) compared to microwells (ø100 µm). The tense state was 4.97 times less, and deformations were 2.96 times fewer. The microtextures hamper the development of thermal fields at 900 °C. Two types of microtextures (210 µm-wide microgrooves and microwells 80 µm in diameter) were produced on the rake faces of the cutting inserts via an innovative and integrated approach (the electrical discharge machining of dielectrics using a multifunctional electro-conductive assisted and wear-resistant TiN coating and TiO<sub>2</sub> powder mixed suspension). The TiN coating was deposited via magnetron vacuum plasma sputtering (95%N<sub>2</sub>/5%Ar). The failure criterion in turning was 400 µm. An increase of 30% in tool wear resistance was demonstrated. |
| first_indexed | 2024-03-11T00:49:33Z |
| format | Article |
| id | doaj.art-169201079908486f886c0035e72f8c4e |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-11T00:49:33Z |
| publishDate | 2023-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-169201079908486f886c0035e72f8c4e2023-11-18T20:29:55ZengMDPI AGMetals2075-47012023-07-01137124110.3390/met13071241Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based AlloyMarina A. Volosova0Anna A. Okunkova1Khaled Hamdy2Alexander P. Malakhinsky3Khasan I. Gkhashim4Department of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Vadkovskiy per. 3A, 127994 Moscow, RussiaDepartment of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Vadkovskiy per. 3A, 127994 Moscow, RussiaDepartment of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Vadkovskiy per. 3A, 127994 Moscow, RussiaDepartment of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Vadkovskiy per. 3A, 127994 Moscow, RussiaDepartment of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Vadkovskiy per. 3A, 127994 Moscow, RussiaThis paper is devoted to the problem of wear resistance in square Si3N4 ceramic cutting inserts, which exhibit high hardness and strength, in combination with brittleness, and are subject to increased mechanical and thermal loads in machining super alloys for aviation purposes (e.g., a nickel-based alloy of Inconel 718 type). Microtextures were proposed to reduce the intensity of the contact loads on the pad between the cutting edge and the workpiece. The simulation of the mechanical and thermal loads demonstrated the superior ability of the faces with the preformed microgrooves (125 µm in width) compared to microwells (ø100 µm). The tense state was 4.97 times less, and deformations were 2.96 times fewer. The microtextures hamper the development of thermal fields at 900 °C. Two types of microtextures (210 µm-wide microgrooves and microwells 80 µm in diameter) were produced on the rake faces of the cutting inserts via an innovative and integrated approach (the electrical discharge machining of dielectrics using a multifunctional electro-conductive assisted and wear-resistant TiN coating and TiO<sub>2</sub> powder mixed suspension). The TiN coating was deposited via magnetron vacuum plasma sputtering (95%N<sub>2</sub>/5%Ar). The failure criterion in turning was 400 µm. An increase of 30% in tool wear resistance was demonstrated.https://www.mdpi.com/2075-4701/13/7/1241coatingcutting ceramicscutting insertselectrical discharge machiningcutting forcesflank wear |
| spellingShingle | Marina A. Volosova Anna A. Okunkova Khaled Hamdy Alexander P. Malakhinsky Khasan I. Gkhashim Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy Metals coating cutting ceramics cutting inserts electrical discharge machining cutting forces flank wear |
| title | Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy |
| title_full | Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy |
| title_fullStr | Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy |
| title_full_unstemmed | Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy |
| title_short | Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy |
| title_sort | simulation of mechanical and thermal loads and microtexturing of ceramic cutting inserts in turning a nickel based alloy |
| topic | coating cutting ceramics cutting inserts electrical discharge machining cutting forces flank wear |
| url | https://www.mdpi.com/2075-4701/13/7/1241 |
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