Plasma Assisted Milling of Heat-Resistant Superalloys

[+] Author and Article Information
L. N. López de Lacalle, J. A. Sánchez, A. Lamikiz, A. Celaya

Department of Mechanical Engineering, University of the Basque Country, Alameda de Urquijo s/n. 48013 Bilbaoe-mail: implomal@bi.ehu.es

J. Manuf. Sci. Eng 126(2), 274-285 (Jul 08, 2004) (12 pages) doi:10.1115/1.1644548 History: Received July 01, 2003; Online July 08, 2004
Copyright © 2004 by ASME
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Welding bead produced by the plasma jet. This may happen when the feed is too small when compared to the plasma intensity
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Temperature at a point 1 mm below the work surface (Haynes 25), when using 650 mm/min feed and 90 A plasma intensity
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Temperature at the plasma spot after switching off the arc (Haynes 25). Spot diameter is approximately 3 mm (60A and 650 mm/min).
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Tool and cutting conditions for Haynes 25
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Flank wear in four teeth, with and without assisting plasma (the tool has seven teeth). When no plasma is used, chipping appears.
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Strain hardening in Haynes 25 after PAM (a) surface previous to machining (b) machined surface ×200 (c) machined surface ×500
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Tool wear as a function of the plasma intensity (machined length: 273 mm). In figure, photo of tool wear. Upper right-hand corner, image of the process.
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Infrared images of the material (a) work surface after applying plasma at 110A and F 972 mm/min (b) work surface after PAM
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Comparison of wear patterns for the same cutting conditions with and without plasma assistance
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Flank wear as a function of machined length (and therefore machining time, l/F, and chip volume, l * ap * ae). Dashed lines shows tool life with and without PAM for the same value of flank wear.
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Strain hardening of Inconel 718 (a) surface previous to machining (without strain hardening) (b) surface after conventional milling (c) surface after PAM
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(a) Heated zone (without machining) ×20 (b) widmanstatten microstructure (basketweaves) of the interface ×500 (c) affected zone after PAM showing that there is still widmanstatten microstructure
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Calculation of Ft and Fv from Fx and Fy
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Main components of the plasma assisted milling system. Below, top view of the plasma spot and the milling tool.
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(a) Chip foot produced when machining with a worn tool (b) Burrs in Haynes 25 when machining with a worn tool
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Experimental equipment of PAM. (a) Inconel 718 or Haynes 25, (b) milling tool, (c) plasma torch, (d) Kistler 9255B force measuring device, (e) plasma generator, (f ) 3 axes vertical machining center, (g) torch positioning system (2 axes)
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Left, infrared image of the PAM process, nozzle drawn in. Right, the same image taken using a CCD camera with a luminosity filter
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Tool and cutting conditions for Inconel 718



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