Superalloys such as Inconel 718 have high strength at elevated temperatures, which make them attractive towards various applications in aerospace industry. However, these materials are considered difficult to machine materials. The state of a workpiece surface after machining is definitely affected by cutting parameters, such as cutting speed, feed rates, drill types and drill geometries. Drilling tests, at different spindle-speed, feed rates, drills and point angles of drill, were conducted in order to investigate the effect of the above parameters on the quality of machined holes and surface integrity of Inconel 718. The quality of machined holes was evaluated in terms of the geometrical accuracy and burr formation. Surface integrity involved the aspect of surface roughness, metallurgical alterations and microhardness of the substrate of the hole surface. High hole quality was observed even at holes produced using worn tools, in relation to dimensions, surface roughness and burr height. However, microhardness measurements and microstructural analysis of work-piece showed significant microstructural changes related with a loss of mechanical properties. In general the cutting parameters have significant effects on the surface quality and surface integrity when drilling Inconel 718 using uncoated carbide drill.
Composite-metal stack is an ideal combination of materials which unites the advantages of each dissimilar material in a substantial weight. However, drilling dissimilar materials has been a challenge since the composite-metal stacks are at demand in industries. It is important to choose the appropriate drill geometry regarding the stacking sequence and utilize proper machining parameters in order to achieve damage free and precession holes. This experimental study was conducted on dry drilling of CFRP/Al2024/CFRP (carbon fiber-reinforced plastic). Four types of twist drills with various geometries, both coated and uncoated, were utilized to study the effect of machining parameters on hole quality. It was observed that increasing feed rate entails an increase in entrance delamination, whereas exit delaminations and fiber fraying at 2nd CFRP exit diminished with increasing feed rate. It was also found that four facet tools performed better than two facet tools in terms of fiber delamination. Most accurate hole was attained on 2nd CFRP; however, it was found that increasing feed significantly affects the hole size on 1st CFRP.
20 April 2011 in The International Journal of Advanced Manufacturing Technology