Dynamic Chip Breaker Design for Inconel 718 Using Positive Angle Tool Holder

Abstract

This study has focused on the chip-breaker design and experimental cutting of Inconel 718 with the designed chip breaker. The process of chip breakage for Inconel 718 with respect to cutting speed, depth of cut, and feed rate then chips and machined surfaces were analyzed from the experimental results. For this purpose, the nickel-based super alloy, Inconel 718, was machined with two layers PVD coated (TiAlN–TiN) carbide insert at feed rates of 0.10, 0.15, 0.20, 0.30 mm/rev, 0.5, 1, 1.5, 2 mm with depth of cuts, and 30, 45, 60, 75 m/min cutting speeds using developed dynamic chip breaker with positive tool holders in dry cutting conditions. Chip pictures and surface roughness (Ra) were recorded. Chip breakability during machining of the Inconel 718 depends on DC motor speed and chip breaker position on the cutting tool. The experimental results show that the designed chip breaker can break long chips at any cutting condition and acceptable surface finish can be achieved. In addition to this, according to cutting conditions, the usages of dynamic chip breaker on the surface of cutting insert are measured between 1% and 44% cooling effects.

Keywords:

• Chip breakability
• Chip breaker
• Chip curl
• Chip flow
• Chip parting
• Cutting insert temperature
• Dynamic chip breaker
• Inconel 718
• Machining
• Mild steel
• Oscillatory feed cutting
• Super alloy
• Surface roughness
• Temperature distribution
• Turning