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      Residual Stresses in High Speed Turning of Nickel-Based Superalloy* Translated title: Eigenspannungen beim Hochgeschwindigkeitsdrehen einer Nickel-Basis-Superlegierung

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          Abstract

          Residual stresses induced by machining operations can be critical for the performance and lifetime of the machined components. This paper investigated the influence of cutting conditions, including the use of cutting fluid, cutting speed and tool flank wear, on the residual stresses in high speed turning of Inconel 718 alloy. X-ray diffraction measurements revealed characteristic residual stress distributions with tensile stresses in a thin surface layer and compressive stresses in a much thicker subsurface layer in all investigated samples. However, the magnitude of the surface tensile stresses and subsurface compressive stresses as well as the size of the tension and compression zone depended on the cutting parameters. Surface tensile residual stresses over 1600 MPa and 1400 MPa were induced by tool flank wear and increased cutting speed, respectively, in dry turning. The effect of cutting induced local plasticity and temperature increase on the observed residual stress distributions was analyzed based on microstructural study by electron channeling contrast imaging and electron backscatter diffraction.

          Kurzfassung

          Eigenspannungen, die bei Zerspanungsprozessen entstehen, können sich negativ auf die Leistungsfähigkeit oder die Lebensdauer von Bauteilen auswirken. Die vorliegende Untersuchung beschäftigt sich mit dem Einfluss der Zerspanbedingungen, einschließlich der Verwendung von Schneidflüssigkeit, der Zerspangeschwindigkeit sowie dem Werkzeugverschleiß, auf die Eigenspannungen von hochgeschwindigkeitsgedrehten Proben aus der Superlegierung Inconel 718. In Röntgenbeugungsmessungen zeigen sich in allen Proben typische Eigenspannungsverteilungen mit Zugeigenspannungen in einer dünnen Randschicht sowie Druckeigenspannungen in einer viel dickeren randnahen Schicht. Jedoch variieren sowohl die Beträge der oberflächlichen Zug- und randnahen Druckeigenspannungen als auch die Größen der beiden Zonen je nach den verwendeten Zerspanungsparametern. Bei der Trockenbearbeitung wurden durch Werkzeugflankenverschleiß Zug- eigenspannungen von über 1600 MPa und durch hohe Schnittgeschwindigkeiten Zugeigenspannungen von 1400 MPa bewirkt. Beim Zerspanungsprozess entstehende lokale plastische Verformungen und Temperaturerhöhungen haben ebenfalls einen Einfluss auf die Eigenspannungen, der mithilfe von EBSD- und ECCI-Messungen untersucht wurde.

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          Most cited references 16

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          A review of strain analysis using electron backscatter diffraction.

          Since the automation of the electron backscatter diffraction (EBSD) technique, EBSD systems have become commonplace in microscopy facilities within materials science and geology research laboratories around the world. The acceptance of the technique is primarily due to the capability of EBSD to aid the research scientist in understanding the crystallographic aspects of microstructure. There has been considerable interest in using EBSD to quantify strain at the submicron scale. To apply EBSD to the characterization of strain, it is important to understand what is practically possible and the underlying assumptions and limitations. This work reviews the current state of technology in terms of strain analysis using EBSD. First, the effects of both elastic and plastic strain on individual EBSD patterns will be considered. Second, the use of EBSD maps for characterizing plastic strain will be explored. Both the potential of the technique and its limitations will be discussed along with the sensitivity of various calculation and mapping parameters.
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            An analysis of the residual stresses generated in Inconel 718™ when turning

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              Surface integrity when machining age hardened Inconel 718 with coated carbide cutting tools

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                Author and article information

                Journal
                htme
                HTM Journal of Heat Treatment and Materials
                Carl Hanser Verlag
                1867-2493
                2194-1831
                27 February 2014
                : 69
                : 1
                : 46-53
                Affiliations
                1 Department of Management and Engineering, SE-58183, Linköping University, Linköping, Sweden
                2 Department of Mechanical Engineering, SE-22100, Lund University, Lund, Sweden
                Author notes
                3 ru.peng@ 123456liu.se (Correspondent author/Kontakt)
                [*]

                Enhanced contribution based upon a presentation at the International Conference on Residual Stresses ICRS9, October 7–9, 2012, in Garmisch-Partenkirchen, Germany

                Article
                HT110211
                10.3139/105.110211
                © 2014, Carl Hanser Verlag, München
                Page count
                References: 18, Pages: 8
                Product
                Self URI (journal page): http://www.hanser-elibrary.com/loi/htme
                Categories
                Fachbeiträge/Technical Contributions

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