Cutting Fluid Effectiveness in the High-Speed Finish Machining of Inconel 718 Using a Whisker-Reinforced Ceramic Tool
This paper aims to investigate the effectiveness of cutting fluid during the high-speed face-turning of superalloy Inconel 718 using chamfered whisker-reinforced ceramic inserts. It addresses this topic by providing a comprehensive understanding of the machinability of Inconel 718 under both dry and...
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MDPI AG
2025-04-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| author | Walid Jomaa Monzer Daoud Hamid Javadi Philippe Bocher |
| author_facet | Walid Jomaa Monzer Daoud Hamid Javadi Philippe Bocher |
| author_sort | Walid Jomaa |
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| description | This paper aims to investigate the effectiveness of cutting fluid during the high-speed face-turning of superalloy Inconel 718 using chamfered whisker-reinforced ceramic inserts. It addresses this topic by providing a comprehensive understanding of the machinability of Inconel 718 under both dry and wet conditions through analytical friction modeling and a detailed analysis of the chip formation process. Two new indexes, named the Area Function (<i data-eusoft-scrollable-element="1">AF</i>) and the Shape Function (<i data-eusoft-scrollable-element="1">SF</i>), were derived to assess the serration intensity of the chips. Particular attention was paid to the interaction between the cutting speed and the cutting fluid. The results showed that wet conditions promote uniform chip formation, more stable forces, a lower coefficient of friction, and the absence of notch wear. At low cutting speed (60 m/min) and dry machining results in high serration intensity (<i data-eusoft-scrollable-element="1">SF</i> = 0.7) and segmentation frequency (<inline-formula data-eusoft-scrollable-element="1"><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline" data-eusoft-scrollable-element="1"><semantics data-eusoft-scrollable-element="1"><mrow data-eusoft-scrollable-element="1"><msub data-eusoft-scrollable-element="1"><mrow data-eusoft-scrollable-element="1"><mi data-eusoft-scrollable-element="1">f</mi></mrow><mrow data-eusoft-scrollable-element="1"><mi data-eusoft-scrollable-element="1">s</mi><mi data-eusoft-scrollable-element="1">e</mi><mi data-eusoft-scrollable-element="1">g</mi></mrow></msub></mrow></semantics></math></inline-formula> = 22.08 kHz) compared to the <i data-eusoft-scrollable-element="1">SF</i> of 0.4 and <inline-formula data-eusoft-scrollable-element="1"><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline" data-eusoft-scrollable-element="1"><semantics data-eusoft-scrollable-element="1"><mrow data-eusoft-scrollable-element="1"><msub data-eusoft-scrollable-element="1"><mrow data-eusoft-scrollable-element="1"><mi data-eusoft-scrollable-element="1">f</mi></mrow><mrow data-eusoft-scrollable-element="1"><mi data-eusoft-scrollable-element="1">s</mi><mi data-eusoft-scrollable-element="1">e</mi><mi data-eusoft-scrollable-element="1">g</mi></mrow></msub></mrow></semantics></math></inline-formula> = 19.69 kHz in wet conditions. The segmentation frequency increases significantly with cutting speed, reaching 71.03 kHz and 63.32 kHz at a cutting speed of 225 m/min for dry and wet conditions, respectively. It was also found that the rate of increase in the tangential force was lower (20.49 N/s) when using cutting fluid at a high cutting speed (225 m/min) compared to dry conditions (27.37 N/s). |
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| issn | 2504-4494 |
| language | English |
| publishDate | 2025-04-01 |
| publisher | MDPI AG |
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| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-0eac490d32904f8faf60af5bd6f07bab2025-08-20T02:28:36ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-04-019412310.3390/jmmp9040123Cutting Fluid Effectiveness in the High-Speed Finish Machining of Inconel 718 Using a Whisker-Reinforced Ceramic ToolWalid Jomaa0Monzer Daoud1Hamid Javadi2Philippe Bocher3Department of Mathematics and Industrial Engineering, Polytechnique Montréal, 2500 ch. de Polytechnique, Montréal, QC H3T 1J4, CanadaDepartment of Mechanical Engineering, College of Engineering, Dhofar University, Salalah 211, OmanDepartment of Mechanical Engineering, École de Technologie Supérieure, 1100 rue Notre-Dame Ouest, Montreal, QC H3C 1K3, CanadaDepartment of Mechanical Engineering, École de Technologie Supérieure, 1100 rue Notre-Dame Ouest, Montreal, QC H3C 1K3, CanadaThis paper aims to investigate the effectiveness of cutting fluid during the high-speed face-turning of superalloy Inconel 718 using chamfered whisker-reinforced ceramic inserts. It addresses this topic by providing a comprehensive understanding of the machinability of Inconel 718 under both dry and wet conditions through analytical friction modeling and a detailed analysis of the chip formation process. Two new indexes, named the Area Function (<i data-eusoft-scrollable-element="1">AF</i>) and the Shape Function (<i data-eusoft-scrollable-element="1">SF</i>), were derived to assess the serration intensity of the chips. Particular attention was paid to the interaction between the cutting speed and the cutting fluid. The results showed that wet conditions promote uniform chip formation, more stable forces, a lower coefficient of friction, and the absence of notch wear. At low cutting speed (60 m/min) and dry machining results in high serration intensity (<i data-eusoft-scrollable-element="1">SF</i> = 0.7) and segmentation frequency (<inline-formula data-eusoft-scrollable-element="1"><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline" data-eusoft-scrollable-element="1"><semantics data-eusoft-scrollable-element="1"><mrow data-eusoft-scrollable-element="1"><msub data-eusoft-scrollable-element="1"><mrow data-eusoft-scrollable-element="1"><mi data-eusoft-scrollable-element="1">f</mi></mrow><mrow data-eusoft-scrollable-element="1"><mi data-eusoft-scrollable-element="1">s</mi><mi data-eusoft-scrollable-element="1">e</mi><mi data-eusoft-scrollable-element="1">g</mi></mrow></msub></mrow></semantics></math></inline-formula> = 22.08 kHz) compared to the <i data-eusoft-scrollable-element="1">SF</i> of 0.4 and <inline-formula data-eusoft-scrollable-element="1"><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline" data-eusoft-scrollable-element="1"><semantics data-eusoft-scrollable-element="1"><mrow data-eusoft-scrollable-element="1"><msub data-eusoft-scrollable-element="1"><mrow data-eusoft-scrollable-element="1"><mi data-eusoft-scrollable-element="1">f</mi></mrow><mrow data-eusoft-scrollable-element="1"><mi data-eusoft-scrollable-element="1">s</mi><mi data-eusoft-scrollable-element="1">e</mi><mi data-eusoft-scrollable-element="1">g</mi></mrow></msub></mrow></semantics></math></inline-formula> = 19.69 kHz in wet conditions. The segmentation frequency increases significantly with cutting speed, reaching 71.03 kHz and 63.32 kHz at a cutting speed of 225 m/min for dry and wet conditions, respectively. It was also found that the rate of increase in the tangential force was lower (20.49 N/s) when using cutting fluid at a high cutting speed (225 m/min) compared to dry conditions (27.37 N/s).https://www.mdpi.com/2504-4494/9/4/123high speed machiningInconel 718cutting fluidceramic toolserrated chipscutting forces |
| spellingShingle | Walid Jomaa Monzer Daoud Hamid Javadi Philippe Bocher Cutting Fluid Effectiveness in the High-Speed Finish Machining of Inconel 718 Using a Whisker-Reinforced Ceramic Tool Journal of Manufacturing and Materials Processing high speed machining Inconel 718 cutting fluid ceramic tool serrated chips cutting forces |
| title | Cutting Fluid Effectiveness in the High-Speed Finish Machining of Inconel 718 Using a Whisker-Reinforced Ceramic Tool |
| title_full | Cutting Fluid Effectiveness in the High-Speed Finish Machining of Inconel 718 Using a Whisker-Reinforced Ceramic Tool |
| title_fullStr | Cutting Fluid Effectiveness in the High-Speed Finish Machining of Inconel 718 Using a Whisker-Reinforced Ceramic Tool |
| title_full_unstemmed | Cutting Fluid Effectiveness in the High-Speed Finish Machining of Inconel 718 Using a Whisker-Reinforced Ceramic Tool |
| title_short | Cutting Fluid Effectiveness in the High-Speed Finish Machining of Inconel 718 Using a Whisker-Reinforced Ceramic Tool |
| title_sort | cutting fluid effectiveness in the high speed finish machining of inconel 718 using a whisker reinforced ceramic tool |
| topic | high speed machining Inconel 718 cutting fluid ceramic tool serrated chips cutting forces |
| url | https://www.mdpi.com/2504-4494/9/4/123 |
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