In the high-stakes world of aircraft engine manufacturing, precision and efficiency are paramount. A recent study published in *Advances in Mechanical and Materials Engineering* (which translates to *Postępy w Mechanice i Inżynierii Materiałowej*) sheds light on how the microgeometry of cutting tools can significantly impact the milling of Inconel 718, a superalloy critical to the energy sector. The research, led by Marcin Szpunar of MTU Aero Engines Polska, offers insights that could revolutionize machining processes and enhance the durability of components used in extreme environments.
Inconel 718 is a nickel-chromium superalloy renowned for its exceptional strength and resistance to corrosion and high temperatures. These properties make it indispensable for aircraft engine components, but they also make it notoriously difficult to machine. The study investigates how the microgeometry of polycrystalline cubic boron nitride (PCBN) inserts affects cutting forces, surface roughness, and tool wear during the milling of Inconel 718.
Szpunar and his team conducted face milling tests using a Ø63 mm tool with unevenly distributed PCBN inserts. They compared the performance of inserts with chamfered cutting edges (15° × 0.2 mm) against those with sharp cutting edges. The experiments were conducted at various cutting speeds ranging from 80 to 300 meters per minute.
The results were revealing. Sharp inserts generated lower cutting forces compared to chamfered inserts, with the axial force being the greatest component for chamfered tools and the lowest for sharp ones. “The cutting edge microgeometry significantly influences the machining performance,” Szpunar noted. “Sharp inserts not only reduced cutting forces but also affected the surface quality and tool wear differently.”
The study found that the dominant tool wear mechanism for both insert types was chipping. However, sharp inserts also exhibited built-up edge formation and, in one case, a significantly deeper crater compared to chamfered inserts, which showed smaller crater depths. This suggests that while sharp inserts may offer advantages in terms of cutting forces and surface roughness, they may also be more prone to certain types of wear.
The implications for the energy sector are substantial. Aircraft engines, power generation turbines, and other high-performance components often rely on Inconel 718 for its durability and resistance to extreme conditions. Optimizing the machining process can lead to significant cost savings, improved component longevity, and enhanced overall performance.
As the energy sector continues to demand higher efficiency and reliability from its components, research like Szpunar’s provides a roadmap for future developments. By understanding the intricate relationship between tool microgeometry and machining performance, manufacturers can fine-tune their processes to achieve better results. This could pave the way for more efficient production methods and ultimately, more advanced and reliable energy solutions.
In the ever-evolving landscape of materials science and engineering, Szpunar’s study serves as a reminder that even the smallest details can have a profound impact. As the energy sector continues to push the boundaries of what is possible, such research will be instrumental in shaping the future of high-performance materials and their applications.