Development and analysis of a low-wear micro-groove tool for turning Inconel 718

Abstract

Abstract In this study, we design a new carbide coated cutting tool for turning Inconel 718 by modifying a standard carbide coated cutting tool to include a micro-groove 0.15\u202fmm away from the cutting edge on the rake face. The total length and width of the micro-groove are 1.8\u202fmm and 1.5\u202fmm, respectively, and the depth is 0.1\u202fmm. The cutting forces, cutting temperatures, wear mechanisms, and tool lifetimes obtained for the original cutting tool and those of the proposed micro-groove tool are compared when turning Inconel 718 under equivalent cutting parameters and conditions. The micro-groove alters the contact between workpiece chips generated in the cutting process and the rake face of the cutting tool, resulting in reduced thermo-mechanical loading, and reduced wear of both the rake and flank faces, compared to the wear observed for the original tool. Scanning electron microscopy and energy dispersive X-ray spectroscopy results demonstrate that abrasive, adhesive, and oxidation wear are the dominant wear mechanisms, and oxidation wear occurs mainly at the edge of contact between the tool and the workpiece.