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The importance of high-temperature materials made of iron aluminides (FeAl) has been increasing in light weight applications, e.g., airplane turbines, due to the high material’s specific strength. However, the highly economic production by means of permanent mold casting involves special microstructures for Fe26Al4Mo0.5Ti1B alloy components leading to difficult machinability for subsequent finishing milling and low surface qualities. Major effects of tool and machining parameter variation incorporating ultrasonic assistance on the milling process and surface integrity are shown. Loads for tool and component surface are significantly adjustable to enable an economic process chain regarding the surface integrity of safety-relevant components.
Wear behavior of innovative niobium carbide cutting tools in ultrasonic-assisted finishing milling
(2023)
The resources of niobium exceed the ones of tungsten by an order of magnitude. With 92%, Brazil is today the main global producer of niobium. Hence, niobium carbides (NbC) are a sustainable and economic alternative to conventionally used cutting materials, especially tungsten carbides (WC). Moreover, NbC can be used in Ni alloy matrix and thus offer significant advantages by substituting WC in Co matrix as cutting materials in terms of health risks and raw material price and supply risk. Based on recent studies which found an increased performance of NbC compared to WC cutting tools in machining higher strength steels, the composition NbC12Ni4Mo4VC was chosen for finish machining of a high-strength steel S960QL in this study. The experiments were carried out on an ultrasonic-assisted 5-axis milling machine using NbC tools specially made to benchmark them with commercially available coated WC cutting inserts. In addition, the influence of a coating system for the NbC inserts is tested and evaluated for its performance in the cutting process. Tool wear and cutting force analyses are implied to identify optimal parameter combinations as well as tool properties for the novel NbC tool. Together with the oscillation of ultrasonic-assisted milling, the loads on the component surface and the tool can be reduced and the wear behavior of the novel NbC tool can be refined. These milling tests are accompanied by standardized wear tests, i.e., pin-on-disc, between the aforementioned material combinations, and the results are correlated with each other. Finally, the behavior when using hard-to-cut materials such as Ni alloys, or innovative materials such as iron aluminide is also being tested, as these are constantly in the focus of machining optimization. With this strategy, comprehensive knowledge is achievable for future efficient application of NbC for milling tools, which have already been researched for decades using WC.