New observations on tool wear mechanism in dry machining Inconel718

Tool wear is a problem in machining nickel-based alloy Inconel718, and it is thus of great importance to understand tool wear. Tool wear mechanism in dry machining Inconel718 with coated cemented carbide tools was analyzed in this paper. CCD and scanning electron microscopy (SEM) equipped with energy dispersive X-ray spectrometer (EDS) were used to study tool wear mechanism. The results show that the main reason which causes cutting tool wear was that the tool materials fall off from the tool substrate in the form of wear debris. In addition element diffusion between tool and workpiece and oxidation reaction all accelerate the formation and the peeling of the wear debris. According to analysis of tool wear mechanism, tool flank wear model was established. The optimal temperature in machining Inconel718 with PVD-coated (TiAlN) tool was obtained through the established model. Excellent experimental agreement was achieved in optimal temperature calculated by the established model. (C) 2011 Elsevier Ltd. All rights reserved.