Sains Malaysiana 42(12)(2013): 1721–1726

Tool Life of TiAlN PVD Coated Carbide Tool in High-Speed End Milling of Untreated Inconel 718 under Minimum Quantity Lubrication Condition

(Jangka Hayat Perkakas Pemotong Berkabida Bersalut TiAlN Menggunakan Pengisar Hujung untuk

Bahan Inconel 718 yang Tidak Dirawat dalam Keadaan Pelinciran Kuantiti Minimum)  

M.S. KASIM², C.H. CHE HARON¹*, J.A. GHANI¹, A.I. GUSRI¹, M.Z.A. YAZID¹ & M.A. SULAIMAN²   

¹Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment

Universiti Kebangsaan Malaysia, 43600 UKM Bangi, Selangor D.E. Malaysia  

²Department of Manufacturing Process, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, 76100 Hang Tuah Jaya, Melaka

Diserahkan: 21 Mac 2012/Diterima: 14 Mei 2012

ABSTRACT

This paper presents the tool life of the end milled Inconel 718, which is part of a material that is difficult to be machined. Previous researchers found that tool life in machining aged Inconel 718 is shorter compared with other materials. However, this observation required further investigation. Thus, a raw grade Inconel was proposed in this experiment. The experiments were performed using TiAlN-coated carbide. The studied milling parameters were the cutting speed, Vc, from 90 to 150 m/min; feed rate, fz, from 0.15 to 0.25 mm/rev; depth of cut, ap, from 0.3 to 0.5 mm; and radial depth of cut, ae=1 mm. The application of the cutting fluid used in this experiment was a minimum quantity lubricant, which had the advantage of cooling effectiveness and low consumption of cutting fluid. The results showed that the feed rate, fz, was the primary factor controlling the tool life. The combination of Vc=115 m/min, fz=0.15 mm/tooth, as well as ap=0.5 mm and ae=0.15 mm gave the longest tool life that served 95.38 min in operation.

Keywords: Ball nose end mill; full factorial; Inconel 718; minimum quantity lubrication

ABSTRAK

Makalah ini membincangkan jangka hayat perkakas pemotong berkabida ketika mengisar hujung bebola bahan Inconel 718. Bahan ini secara umumnya diketahui sebagai salah satu bahan yang sukar dimesin. Kajian terdahulu mendapati pemotongan Inconel 718 yang dikerastua telah memendekkan jangka hayat pemotong. Ini memerlukan kajian lanjut dan Inconel 718 mentah dicadangkan untuk kajian ini. Uji kaji ini dijalankan dengan menggunakan pemotong berkabida bersalut endapan wap fizikal TiAlN. Parameter pemesinan melibatkan kederasan memotong Vc = 90-150 m/min, kadar suapan, fz = 0.15-0.25 mm/rev dan kedalaman pemotongan sebanyak 0.3-0.5 mm. Mengambil kira keberkesanan kesan penyejukan dan penjimatan, uji kaji ini dijalankan dalam keadaan pelinciran kuantiti minimum. Kajian mendapati kadar suapan adalah faktor utama kesan terhadap jangka hayat. Melalui uji kaji ini, jangka hayat mata alat pemotongan telah direkodkan selama 95.38 min dengan parameter Vc = 115 m/min, fz = 0.15 mm/gigi dan ap = 0.5 mm dan ae= 0.15 mm.

Kata kunci: Faktoran penuh; Inconel 718; pelinciran kuantiti minimum; pengisar hujung bebola

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*Pengarang untuk surat-menyurat; email: chase@eng.ukm.my