Method of Data Selection for Turning of Inconel 718 Alloy Obtained by Casting and Laser Sintering Powder

Area of Science:

• Materials Science
• Manufacturing Engineering
• Additive Manufacturing

Background:

• Direct Metal Laser Sintering (DMLS) is an advanced additive manufacturing technique for creating complex metal parts.
• Inconel 718 is a high-performance superalloy widely used in demanding applications.
• Machining challenges arise with DMLS-processed Inconel 718 due to its unique microstructure and properties.

Purpose of the Study:

• To investigate the machining characteristics of DMLS Inconel 718 during longitudinal turning.
• To establish an optimization procedure for finishing cutting parameters.
• To minimize specific cutting force while ensuring high machined surface quality.

Main Methods:

• Longitudinal turning experiments were conducted using cubic boron nitride (CBN) tool inserts.
• Analysis of cutting forces, specific cutting forces, and surface roughness parameters.
• Comparative study with cast Inconel 718.
• Investigation of chip morphology and material hardening during machining.

Main Results:

• Machining DMLS Inconel 718 resulted in approximately 32% lower cutting forces compared to cast Inconel 718.
• Variability in material hardening state and specific cutting force was observed, influenced by the cutting layer's cross-sectional shape.
• An optimization algorithm demonstrated a 22% reduction in specific cutting force by modifying the cutting layer's cross-section.

Conclusions:

• The study provides insights into optimizing the machining of DMLS Inconel 718.
• Adjusting cutting parameters, particularly the cutting layer's cross-section, can significantly reduce machining forces.
• The findings contribute to more efficient and cost-effective manufacturing processes for additively manufactured Inconel 718 components.