Links Between Machining Parameters and Surface Integrity in Drilling Ni-Superalloy

This is an author-deposited version published in : http://oatao.univ-toulouse.fr/ Eprints ID : 6485

To link to this article : DOI: 10.4028/www.scientific.net/AMR.112.171 URL : http://dx.doi.org/10.4028/www.scientific.net/AMR.112.171

O

pen

A

rchive

T

OULOUSE

A

rchive

O

uverte (

OATAO

)

OATAO is an open access repository that collects the work of Toulouse researchers and makes it freely available over the web where possible.

To cite this version :

Dutilh, Vincent and Dessein, Gilles and Alexis, Joël and Perrin, Géraldine Links Between Machining Parameters and Surface Integrity in Drilling Ni-Superalloy. (2010) Advanced Materials Research, vol. 112 . pp. 171-178. ISSN 1662-8985

Any correspondence concerning this service should be sent to the repository administrator: staff-oatao@listes.diff.inp-toulouse.fr

Links between machining parameters and surface integrity in drilling

Ni-superalloy

9LQFHQW'87,/+

*LOOHV'(66(,1

-RsO$/(;,6

*pUDOGLQH3(55,1

_

G_{JHUDOGLQHSHUULQ#WXUERPHFDIU}

.H\ZRUGV8GLPHW'ULOOLQJ6XUIDFH,QWHJULW\3URFHVV0RQLWRULQJ



$EVWUDFW ,Q DHURVSDFH LQGXVWU\ WKH PDQXIDFWXULQJ RI FULWLFDO SDUWV KLJK HQHUJ\ FRPSRQHQWV

UHTXLUHV DQ LPSRUWDQW YDOLGDWLRQ SURFHVV WR JXDUDQWHH WKH TXDOLW\ RI WKH SURGXFHG SDUWV DQG WKXV WKHLU IDWLJXH OLIHF\FOH *OREDOO\ WKLV YDOLGDWLRQ FRQVLVWV LQ IUHH]LQJ WKH FXWWLQJ FRQGLWLRQV XVLQJ PHWDOOXUJLFDO DQDO\VLV RU IDWLJXH WULDOV DQG D WHVW RQ WKH ILUVW DUWLFOH 7KLV SURFHVV LV H[WUHPHO\ FRPSOH[DQGH[SHQVLYH,QWKLVZD\HVWDEOLVKLQJWKHFRUUHODWLRQEHWZHHQWKHFXWWLQJFRQGLWLRQVDQG WKHVXUIDFHLQWHJULW\ZLOOKHOSXVWRRSWLPL]HWKHPDQXIDFWXUHRIWKRVHSDUWV

,Q WKLV DUWLFOH E\ WKH PHDQV RI DQ H[SHULPHQWDO PHWKRG ZH GHILQH D GRPDLQ RI YDOLGDWLRQ E\ FRPELQLQJWKHFXWWLQJFRQGLWLRQVDFFRUGLQJWRWKHFODVVLFFULWHULDHVWDEOLVKHGE\$)125( QRUP&RXSOH7RRO0DWHULDODQGWKHFULWHULDRIVXUIDFHLQWHJULW\IRUWKHGULOOLQJRID1LFNHOEDVH VXSHUDOOR\

7KH H[SHULPHQWDO GHYLFH FRQVLVWV LQ GULOOLQJ D ‘ PP KROH RQ D D[LV PLOOLQJ FHQWUH LQVWUXPHQWHGE\DFRPSRQHQWV.LVWOHUG\QDPRPHWHU)[)\)]DQG0]DVSLQGOHSRZHUVHQVRU ³:DWWSLORWH´ DQG WKUHH DFFHOHURPHWHUV SODFHG IROORZLQJ WKH GLUHFWLRQV ; < DQG = 6FDQQLQJ (OHFWURQ0LFURVFRS\6(0REVHUYDWLRQVPLFURKDUGQHVVWHVWVDQGWRSRJUDSKLFPHDVXUHPHQWVZLWK DQ RSWLFDO SURILORPHWHU DUH FDUULHG RXW WR FKDUDFWHUL]H WKH PHWDOOXUJLFDO VWDWH RI WKH KROHV PDQXIDFWXUHG

)LQDOO\ FRUUHODWLRQV ZHUH UHVSHFWLYHO\ PDGH EHWZHHQ WKH FXWWLQJ FRQGLWLRQV WKH UHFRUGHG VLJQDOV DQGWKHPHWDOOXUJLFDOVWDWHRIWKHKROHV

,QWURGXFWLRQ

*DV WXUELQH FRPSRQHQWV VXFK DV GLVFV DUH VXEMHFWHG WR VHYHUH RSHUDWLQJ FRQGLWLRQV 7KH PDQXIDFWXULQJ RI WKHVH GLVFV LV YHU\ GLIILFXOW DQG LV VXEPLWWHG WR LPSRUWDQW YDOLGDWLRQSURFHVVHV 7KH PDFKLQLQJ RI 1LFNHO±EDVH VXSHUDOOR\ LV FRPSOH[ DQG VRPH VPDOO YDULDWLRQV RI WKH FXWWLQJ FRQWH[WPD\JHQHUDWHVXUIDFHLQWHJULW\DQRPDOLHV7KHVHDQRPDOLHVLIWKH\RFFXULQFULWLFDOSDUWV PD\KDYHFDWDVWURSKLFFRQVHTXHQFHV9DOLGDWLRQSURFHVVHVGXULQJZKLFKPDFKLQLQJFRQGLWLRQVDUH ³IUR]HQ´ DIWHU D PHWDOOXUJLFDO DQDO\VLV DUH WRGD\ WKH RQO\ ZD\ WR JXDUDQWHH WKH ³KHDOWK´ RI WKH SURGXFHGSDUWV,QWKLVFRQWH[W$&&(17SURMHFW$GDSWLYH&RQWURORI0DQXIDFWXULQJ3URFHVVHVIRU D1HZ*HQHUDWLRQRI-HW(QJLQH&RPSRQHQWVZLOODOORZWKH(XURSHDQ$HUR(QJLQHPDQXIDFWXUHUV WRLPSURYHWKHLUFRPSHWLWLYHQHVVE\DSSO\LQJDGDSWLYHFRQWUROWHFKQLTXHVWRWKHPDQXIDFWXULQJRI WKHLUFRPSRQHQWV 7KHDLPRIWKLVZRUNLVWRHVWDEOLVKOLQNVEHWZHHQFXWWLQJFRQGLWLRQVDQGVXUIDFHLQWHJULW\7KHXVH RIWKHILUVWVWHSRIWKH&20&RXSOH7RRO0DWHULDOPHWKRGRORJ\DOORZVWRLGHQWLI\RSWLPDOFXWWLQJ FRQGLWLRQV DFFRUGLQJ WR VSHFLILF FXWWLQJ IRUFHV WRRO ZHDU DQG URXJKQHVV :H PXOWLSO\ ZD\V WR PHDVXUH VSHFLILF FXWWLQJ IRUFHV LQ RUGHU WR FKDUDFWHUL]H WKH VHQVLELOLW\ DQG WKH TXDOLW\ RI WKRVH GLIIHUHQWV\VWHPV7KHQZHWU\WRFRUUHODWHWKHFXWWLQJFRQGLWLRQVZLWKWKHVXUIDFHLQWHJULW\GHILQHG E\ (XURSHDQ $HUR (QJLQH PDQXIDFWXUHUV $&&(17 SDUWQHUV )LQDOO\ ZH PDNH VRPH FRUUHODWLRQV EHWZHHQVXUIDFHLQWHJULW\DQGSURFHVVPRQLWRULQJVLJQDOV

6WDWHRIWKHDUW

1LFNHOEDVHVXSHUDOOR\VVXFKDV8',0(7DUHIUHTXHQWO\FKRVHQIRUWXUELQHGLVFDSSOLFDWLRQV,Q JHQHUDO WKHVH DOOR\V KDYH JRRG UHVLVWDQFH DJDLQVW FRPELQDWLRQV RI IDWLJXH FUHHS R[LGDWLRQ DQG FRUURVLRQGDPDJHV7KHFRPSRVLWLRQRI8',0(7/LLVJLYHQLQ7DEOH,WLVFRQVWLWXWHGE\DQ DXVWHQLWLF )&& IDFHG FHQWHUHG FXELF γ  PDWUL[ VWUHQJWKHQHG PDLQO\ E\ FRKHUHQW 1LFNHOULFK 7L$O1 γ¶ SUHFLSLWDWHV DQG VRPH HOHPHQWV VXFK DV FREDOW FKURPH PRO\EGHQXP DQG WXQJVWHQ 3ULPDU\ FRDUVH SUHFLSLWDWHV γ¶ DUH FOHDUO\ YLVLEOH DW WKH JUDLQERXQGDULHV DQG ILQH FXERLGDOγ¶DUH HPEHGGHGFRKHUHQWO\WKURXJKRXWWKHγPDWUL[>@



(OHPHQWV 1L &U &R 7L 0R $O : )H % 6L 0Q &X & 3 6

PLQ %DVH              

PD[               

7DEOH&RPSRVLWLRQRI8',0(7/,>ZHLJKW@ 

0DQ\ VWXGLHV RQ WKH GLIILFXOW\ LQ PDFKLQLQJ QLFNHOEDVH VXSHUDOOR\ ZHUH SHUIRUPHG EXW IHZ RQ GULOOLQJDQGHYHQOHVVRQGULOOLQJ8GLPHW>@)XUWKHUPRUHWKHPDMRULW\RISDSHUVGHDO ZLWKWRROZHDUDQGSURGXFWLYLW\LQPDFKLQLQJ1LFNHOEDVHVXSHUDOOR\,QKROHPDNLQJWKHWRROOLIH PD\EHZHOOFRQWUROOHGE\PHDVXULQJWRROIODQNZHDUEXWWKLVGRHVQ¶WJXDUDQWHHWKHVXUIDFHLQWHJULW\ >@7KHORZWKHUPDOFRQGXFWLYLW\RIWKLVPDWHULDOOHDGVWRKLJKFXWWLQJWHPSHUDWXUHVDWWKHUDNHIDFH ZKLFKDFFHOHUDWHVWRROIODQNZHDU7KHWHQGHQF\RIWKHγPDWUL[WRZRUNKDUGHQLQJDQGWKHUDSLG IODQNZHDUOHDGWRDEXLOWXSHGJHIRUPDWLRQ%XLOWXSHGJHKDVFRQVHTXHQFHVRQVXUIDFHURXJKQHVV > @ ,Q DHUR HQJLQH FRPSRQHQW PDQXIDFWXULQJ D ILQLVKLQJ RSHUDWLRQ OLNH UHDPLQJ RU PLOOLQJ LV QHFHVVDU\ WR HOLPLQDWH UHVLGXDO VWUHVVHV DQG ZRUN KDUGHQLQJ JHQHUDWHG E\ WKH URXJKLQJ DQG WR LPSURYHWKHURXJKQHVVVSHFLILFDWLRQV>@

2QH RI WKH PRVW GLIILFXOW VWHSV LQ DHURVSDFH LQGXVWU\ PDFKLQLQJ LV WKH UHVSHFW RI WKH VXUIDFH LQWHJULW\ DQG WKH XQGHUVWDQGLQJ RI WKH LPSRUWDQFH RI HDFK DQRPDO\ IRU SDUW IDWLJXH OLIH $Q LPSRUWDQWVWXG\RQWKLVWRSLFZDVWKH0$1+,53SURMHFW>@LQZKLFKWKH\GHPRQVWUDWHGDUHGXFWLRQ RI(WR(F\FOHVRQIDWLJXHOLIHIRUVDPSOHV,QFRQHODQG7LKDYLQJWKHIROORZLQJ DQRPDOLHV VPHDULQJ ORFDO PLFURVWUXFWXUH GHIRUPDWLRQ DGLDEDWLF VKHDU EDQG RU KHDY\ GLVWRUWLRQ 2WKHUVWXGLHVKDYHGHPRQVWUDWHGWKHLQIOXHQFHRIZKLWHOD\HURUUHVLGXDOVWUHVVHVRQIDWLJXHOLIH> @3HUULQ>@KDVGHILQHGIRXUW\SHVRI³DQRPDO\KROHV´RXWRIWKHGRPDLQGHILQHGE\WKH&20 PHWKRGRORJ\ >@ 7KH IRXU W\SLFDO KROHV DUH GHVFULEHGE\ WKH FRPELQDWLRQ RI WKH WKUHH IROORZLQJ DQRPDOLHV LVRODWHG VPHDULQJ VKHDU DGLDEDWLFEDQGDQGWKHUPRPHFKDQLFDODIIHFWHG]RQH2XWRI WKHIRXUW\SLFDOKROHVWKHRQHZLWKH[FOXVLYHO\³QRQHPEHGGHGLVRODWHGVPHDULQJ´GRHVQ¶WLPSDFW WKHSDUWIDWLJXHOLIHF\FOH7KLVXQGHUOLQHVWKHGLIILFXOW\RIGHILQLQJDQGGHWHFWLQJVXUIDFHLQWHJULW\ DQRPDOLHV

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∅PPIRUJHGEDUVXVXDOO\XVHGIRUWXUELQHGLVFV PDQXIDFWXULQJ7KHVHEDUVKDYHWKHVDPHKHDWWUHDWPHQWVDVWKHGLVFVVROXWLRQDQGDJHGWRREWDLQ WKHQHDUHVWFKDUDFWHULVWLFVWRWKHGLVFVRQHVVDPHPLFURVWUXFWXUHVDPHJUDLQVL]H•$670DQG VDPHKDUGQHVV•+97KHRQO\GLIIHUHQFHEHWZHHQWKHGLVFVDQGWKHEDUVLVWKHJUDLQIORZ GXHWRWKHODVWIRUJLQJRSHUDWLRQ

7KHWRROLVD∅PPGULOO,VFDU&KDPGULOOZLWKDQLQWHUFKDQJHDEOH7L$O1FRDWHGFDUELGHKHDG 7KLV GULOO KDV WKH SDUWLFXODULW\ RI KDYLQJ D YHU\ VKRUW PDUJLQ  PP ZKLFK DYRLGV DQRPDOLHV JHQHUDWHGE\IULFWLRQVDOODORQJWKHKROH

$OOWKHWULDOVZHUHPDGHRQDQ2O\PSLF9.D[LVYHUWLFDOPLOOLQJFHQWHUXVLQJDN:VSLQGOH PRWRUDQGD)DQXF2L0%QXPHULFDOFRQWUROOHU

7KH PDFKLQH ZDV LQVWUXPHQWHG E\ D  FRPSRQHQWV .LVWOHU G\QDPRPHWHU )[ )\ )] DQG 0] D VSLQGOHSRZHUVHQVRU³:DWWSLORWH´DQGWKUHHDFFHOHURPHWHUVSODFHGIROORZLQJWKHGLUHFWLRQV;< DQG= )LQDOO\ZHGHVLJQHGDQDVVHPEO\WRPDQDJHWKHGULOOLQJRIKROHVSHUEDUDQGWRDOZD\VPDNHWKRVH KROHVDWWKHFHQWHURIWKHG\QDPRPHWHU,QWKLVW\SHRIG\QDPRPHWHUWKHWRUTXHLVPHDVXUHGE\D VHQVRUDQGQRWFDOFXODWHGDVLQDFRPSRQHQWVG\QDPRPHWHUILJXUHD     )LJXUHD([SHULPHQWDOVHWXSDQGE([SHULPHQWDOSODQ ([SHULPHQWDOSODQ

7KH REMHFWLYH RI WKLV ZRUN LV WR HVWDEOLVK WKH UHODWLRQV WKURXJK WKH FXWWLQJ FRQGLWLRQV EHWZHHQ SURFHVV PRQLWRULQJ VLJQDOV DQG VXUIDFH LQWHJULW\ DQRPDOLHV ILJXUH E )RU RXU H[SHULPHQWDO SURFHGXUH ZH FKRVH WKH ILUVW SDUW RI &20 PHWKRGRORJ\ WR GHILQH D ILUVW GRPDLQ RI FXWWLQJ FRQGLWLRQV:HGLGQ¶WSHUIRUPWKHWRROOLIHVWXG\DVH[SODLQHGLQWKHVHFRQGSDUWRIWKHQRUP

7KH RSHUDWLRQ LV D ∅ PP GULOOLQJ LQ D SUHKROH ∅ PP PDGH E\ HOHFWULFDO GLVFKDUJH PDFKLQLQJ7KLVRSHUDWLRQLVUHSUHVHQWDWLYHWRWKHPDFKLQLQJSURFHVVRIDFULWLFDOSDUWGLVFZKHUH WKHSUHKROH∅PPLVDFRULQJWRPDNHPHWDOOXUJLFDODQDO\VLVRQSDUWPDWHULDO

7HVWVLQFURVVDVGHILQHGLQWKH&20PHWKRGRORJ\FRQVLVWVZLWKWKHKHOSRIIRUFHRUSRZHUVHQVRU LQ UHVHDUFKLQJ WKH FXWWLQJ VSHHG DQG WKH IHHG FRUUHVSRQGLQJ WRORZHUVSHFLILFFXWWLQJFRHIILFLHQWV .F$VGHILQHGLQWKHQRUPZHEHJDQWKHWULDOVZLWKWKHUHVHDUFKRIWKHUHIHUHQFHFXWWLQJVSHHG ZLWK IL[HG IHHG 7KH ILUVW IHHG FKRVHQ ZDV WKHRQHXVHGLQSURGXFWLRQ7KHQZLWKWKLVUHIHUHQFH FXWWLQJVSHHGZHVHDUFKHGWKHUHIHUHQFHIHHG7KHWHVWHGFXWWLQJVSHHGVDUHUHSUHVHQWHGRQILJXUH 6SHFLILF FXWWLQJ FRHIILFLHQWV DUH FDOFXODWHG E\ XVLQJ HTXDWLRQV  H[WUDFWHG IURP WKH ( QRUP>@ZKLFKZDVGHILQHGIRUGULOOLQJLQVROLG,QRXUFDVHZHZHUHFORVHWRDWXUQLQJRSHUDWLRQ ZLWK D UDGLDO HQJDJHPHQW RI  PP +RZHYHU WKHVH HTXDWLRQV UHYHDOHG D JRRG EHKDYLRU DQG DOORZHG TXLFNO\ WR UHYHDO D FXWWLQJ GRPDLQ :H WHVWHG WZHOYH GLIIHUHQW FXWWLQJ VSHHGV DQG HLJKW GLIIHUHQWIHHGV:HPDFKLQHGHDFKKROHZLWKDQHZWRROWRPLQLPL]HWKHLQIOXHQFHRIWKHFXWWLQJ HGJHSUHSDUDWLRQDQGWRKDYHDJRRGUHSURGXFLELOLW\   &RPSRQHQWV .LVWOHU '\QDPRPHWHU $FFHOHURPHWHUV 6SLQGOHD[LV 6DPSOH = ; < I 9 G 3  3 N F F F FF × × × =  I G 0  0 NFF F F × × = ð  I G ) )] NFI I × × =  D E

5HVXOWV

,GHQWLILFDWLRQ RI RSWLPDO FXWWLQJ FRQGLWLRQV 7KH FXWWLQJ FRQGLWLRQV ZLQGRZ ILJXUH  ZDV

HVWDEOLVKHGDFFRUGLQJWRVSHFLILFFXWWLQJIRUFHV.FI)].FF0].FF3FDQGLQUHJDUGVWR WKHGLIIHUHQWPHDVXUHPHQWV\VWHPVHPSOR\HGILJXUH7RHVWDEOLVKWKHRSWLPDOFXWWLQJVSHHGZH VHDUFKHGWKHORZHUSRLQWRIWKHFXUYHIRUWKHFXWWLQJVSHHGJUDSKILJXUHDDQGWKHLQIOH[LRQSRLQW RIWKHFXUYHIRUWKHIHHGILJXUHE2QILJXUHVDDQGEZHIRXQGDQRSWLPDOSRLQWDV9F  PPLQ DQG I   PPWU7KLVRSWLPDOSRLQWFRUUHVSRQGHGWRWKHORZHUIRUFHQHFHVVDU\WRFXW PP_{RIPDWHULDO}             .F 1 P P ð 9FPPLQ .FF0F .FF3F         .F 1 P P ð IPPWU .FI .FF0F .FF3F                     5D — P  5] — P  9FPPLQ 5] 5D                 & \O LQGH U WD SH U — P  FL UF XO DU LW\ P P  IPPWU &LUFXODULW\ &\OLQGHUWDSHU  )LJXUHD6SHFLILFFXWWLQJIRUFHVFXWWLQJVSHHGE6SHFLILFFXWWLQJIRUFHVIHHGF5RXJKQHVV FXWWLQJVSHHGG+ROHJHRPHWU\IHHG  ,Q RXUFDVHWKHGHILQLWLRQRIWKDWSRLQWLVQRWHDV\GXHWRWKHLQFHUWLWXGHRIWKHYDOXHWDNHQLQWR DFFRXQWIRUWKH.FFDOFXOXV7KXVZHKDYHGHFLGHGWRHVWDEOLVKDFXWWLQJFRQGLWLRQVZLQGRZ:H GHOLPLWHGUDQJHVRIVSHHGUHGOLQHVRQILJXUHVDFFRUGLQJWRWKHIROORZLQJSDUDPHWHUV6SHFLILF FXWWLQJFRHIILFLHQWV.FF.FIIODQNDQGFOHDUDQFHZHDURIWKHWRRODQGURXJKQHVVILJXUHF5D 5]DQGKROHJHRPHWU\ILJXUHGFLUFXODULW\DQF\OLQGHUWDSHU7KHVHODVWWZRSDUDPHWHUVDUHQRW XVXDOO\ XVHG LQ WKH &20 PHWKRGRORJ\ :H FKRVH WKHP DV WKH\ DUH QRQGHVWUXFWLYH DQG HDV\ WR FRQWURO



6XUIDFH LQWHJULW\ DQDO\VLV 0HWDOORJUDSKLF H[DPLQDWLRQV ZHUH PDGH LQ RUGHU WR GHILQH FXWWLQJ

VSHHG GRPDLQ DFFRUGLQJ WR WKH VXUIDFH LQWHJULW\ GHILQLWLRQ 2EVHUYDWLRQV ZHUH SHUIRUPHG ZLWK D VFDQQLQJ HOHFWURQ PLFURVFRSH 6(0)(* -(2/  ) DQG DQ RSWLFDO SURILORPHWHU 9((&2 17

7KHVXUIDFHLQWHJULW\GHILQLWLRQDVVKRZQLQWDEOHLVDFODVVLILFDWLRQRIDQRPDOLHVLQWKUHHPDLQ WRSLFVDQGVL[FDWHJRULHV([DPSOHVRIDQRPDOLHVDQGFULWHULDWRFKDUDFWHUL]HDQRPDOLHVDUHJLYHQ ,Q WKLV SDSHU ZH IRFXV RQ WZR VXUIDFH LQWHJULW\ WRSLFV WKH VXUIDFH WRSRJUDSK\ DQG WKH PLFURVWUXFWXUH PHWDOOXUJLFDO FKDQJHV ,Q WKH KROHV VWXGLHG WKH PDLQ DQRPDOLHV REVHUYHG DUH FKDWWHUV VPHDULQJ PLFURFUDFNV  —P OHQJWK ILJXUH  GLVWRUWHG OD\HUV DQG KHDW DQG PHFKDQLFDODIIHFWHGOD\HUVILJXUH

D E



7RSLFV 6XUIDFHWRSRJUDSK\ _{0HWDOOXUJLFDOFKDQJHV}0LFURVWUXFWXUH 0HFKDQLFDOSURSHUWLHV &DWHJRULHV 6XUIDFH0DFUR_DQRPDOLHV 6XUIDFH0LFUR

DQRPDOLHV +HDWDIIHFWHG ]RQH 0HFKDQLFDO DIIHFWHG ]RQH +HDWDQG PHFKDQLFDO DIIHFWHG]RQH 0DWHULDO KDUGQHVV FKDQJHV 5HVLGXDO VWUHVVHV 6XUIDFH LQWHJULW\ DQRPDOLHV 6FRUHV&UDFNV ,QFOXVLRQV 2UDQJHSHHO &KDWWHU %XUU )ODNLQJ 6PHDULQJ FKLSV /DSV 3OXFNLQJ 5HFDVWOD\HU 5HGLVVROXWLRQ RISKDVHV 'LVWRUWHG OD\HU :KLWHOD\HU 5HFU\VWDOOLVHG ]RQH 'HYLDWLRQ RI0LFUR KDUGQHVVLQ VXUIDFHRU LQGHSWK 'HYLDWLRQ RIUHVLGXDO VWUHVVHVLQ VXUIDFHRU LQGHSWK 7DEOH6XUIDFHLQWHJULW\GHILQLWLRQ   )LJXUH6XUIDFHWRSRJUDSK\DQRPDOLHVDFKDWWHUEPLFURFUDFNVFVPHDULQJ  2QILJXUHEZHREVHUYHDGLVWRUWLRQRISULPDU\ȖµDQGDGLVVROXWLRQRISULPDU\DQGVHFRQGDU\Ȗµ SKDVHV ZKLFK LQGLFDWHV D ORFDO RYHUKHDWLQJ DQG PHFKDQLFDO VWUHVVHV 7KLVDQDO\VLVZDVFRUUHODWHG ZLWK DQ ;UD\ PDS SHUIRUPHG ZLWK (QHUJ\ 'LVSHUVLYH 6SHFWURPHWU\ 6'' %58&.(5 DQG E\ PLFURKDUGQHVVSURILOHZKHUHZHREVHUYHWKHVWUDLQKDUGHQLQJLQVXEVXUIDFH0RUHDQDO\VLVZLWK UHVLGXDOVWUHVVHVPHDVXUHPHQWVZLOOFRPSOHWHWKRVHREVHUYDWLRQV

7KH DQDO\VLV RI WKH KROHV DQG WKH FRPSDULVRQ ZLWK WKH VSHFLILF FXWWLQJ IRUFHV KDG SHUPLWWHG WR GHWHUPLQH VRPH DFFHSWDEOH YDOXHV IRU WKH DQRPDOLHV REVHUYHG &KDWWHUV ZLWK JURRYHV XQGHU SUHGHWHUPLQHGURXJKQHVVYDOXHV5D —PDQG5] —PDUHDFFHSWDEOH0LFURFUDFNVYLVLEOH DW6(0PDJQLWXGH;DUHQRWDFFHSWDEOH'LVWRUWHGOD\HULVDFFHSWDEOHXQGHU—PWKLFNQHVV $QGKHDWDQGPHFKDQLFDODIIHFWHGOD\HURUZKLWHOD\HULVWRWDOO\SURKLELWHG

6XUIDFH LQWHJULW\ DQDO\VLV SHUPLWWHG WR GHWHUPLQH D QHZ FXWWLQJ VSHHG GRPDLQ VPDOOHU WKDQ WKH SUHYLRXVRQHGHILQHGZLWK&20PHWKRGRORJ\ILJXUH   )LJXUH&XWWLQJVSHHGVDQGVXUIDFHLQWHJULW\GRPDLQV            6SHHGVWHVWHG V V V 7RROEUHDNDJH 'LVWRUWHGOD\HUDQG +HDWDQGPHFKDQLFDODIIHFWHGOD\HU 6PHDULQJDQGFKDWWHUV$FFHSWDEOHVXUIDFHLQWHJULW\GRPDLQ &20'RPDLQ I PP WU   9FPPLQ V &X WWLQ J WLP H 0LFURFUDFNV D E F & XW WLQJGL UHFW LRQ

6LJQDOVILOWUDWLRQVDQGFRQIURQWDWLRQV6LJQDOVIURPSURFHVVPRQLWRULQJDUHFKDUDFWHUL]HGE\WKH TXDQWLW\PHDVXUHGWKHVHQVLELOLW\DQGWKHILOWHULQJVDPSOLQJ7KHFRQIURQWDWLRQRIWKUHHGLIIHUHQW V\VWHPVVXFKDVSRZHUIRUFHVDQGDFFHOHUDWLRQGHILQHVWKHLUUHOHYDQFHWRZDUGVWKHVXUIDFHLQWHJULW\ :LWKDORZSDVVILOWHULQJDQGZLWKDFXWRIIIUHTXHQF\HTXDOWRWRRWKIUHTXHQF\ZHFRUUHODWHGWKH SRZHUFRQVXPHGE\WKHVSLQGOHDQGWKHFXWWLQJSRZHUFDOFXODWHGHTXDWLRQZLWKWKHWRUTXHDQG WKHIHHGIRUFHPHDVXUHGE\WKHG\QDPRPHWHU,QWKHVDPHZD\ZLWKDKLJKSDVVILOWHUZLWKWKHVDPH FXWRIIIUHTXHQF\ZHFDQFRUUHODWHVLJQDOVIURPDFFHOHURPHWHUVDQGG\QDPRPHWHU+RZHYHUWKHVH FRUUHODWLRQVDUHRQO\WHPSRUDODQGZLOOEHFRPSOHWHGE\DIUHTXHQF\DQDO\VLV

7KH FXWWLQJ SRZHU FXUYH JLYHQ E\ WKH VSLQGOH SRZHU VHQVRU ³:DWWSLORWH´ LV DOZD\V DERYH WKH FXWWLQJ SRZHU FXUYH FDOFXODWHG E\ WKH G\QDPRPHWHU $ FRHIILFLHQW  WR  IRU RXU UDQJH RI SRZHU QHHGV WR EH DGGHG LQ RUGHU WR VXSHUSRVH WKHFXUYHV H[DFWO\ 7KLV GLIIHUHQFH LV GXH WR WKH ³:DWWSLORWH´XQORDGHGSRZHUFRUUHFWLRQDQGGHSHQGVRQWKHJOREDOSRZHUFRQVXPHG$FWXDOO\WKH DPRXQWRISRZHUFRQVXPHGVSHFLILFDOO\E\WKHVSLQGOHPRWRULVQRWWKHVDPHZKHQLWLVXQORDGHGDV ZKHQLWLVLQFKDUJH7KLVVKRZVWKDWWKHSRZHUVHQVRULVQRWDYDLODEOHIRUDEVROXWHPHDVXUHPHQW





&RUUHODWLRQ VXUIDFH LQWHJULW\ ± 3URFHVV 0RQLWRULQJ ,Q WKLV SDUDJUDSK ZH SURSRVH VRPH

FRUUHODWLRQV EHWZHHQ VXUIDFH LQWHJULW\ DQRPDOLHV DQG VLJQDOV UHFRUGHG 7KH ILUVW RQH ZDV WKH GHWHFWLRQRIVRPHEUXWDOFKDQJHVRIFXWWLQJSRZHUZLWKVRPHGHHSHUFXWWLQJVFRUHV  )LJXUHD&RUUHODWLRQURXJKQHVV3RZHUE'HSRVLWRI8GLPHWRQFXWWLQJHGJHRIWKHWRRO  2QILJXUHDZHFDQVHHH[DFWO\WKHVDPHSDWWHUQIRUWKHSRVLWLRQRIWKHSHDNVRQERWKFXUYHV7KH URXJKQHVVSURILOHZDVPHDVXUHGZLWKDQRSWLFDOSURILORPHWHURQDZLGHEDQGPPDOODORQJWKH KROH7KLVFXUYHLVVZLWFKHGXSVLGHGRZQLQRUGHUWRWDOO\WKHLQFUHDVHLQSRZHUZLWKWKHLQFUHDVHRI WKHUHPRYHGPDWHULDO7KHDPSOLWXGHRIVLJQDOVYDULDWLRQVVHHPVSURSRUWLRQDODQGIXUWKHUDQDO\VLV ZLOOEHPDGHWRFRQILUPWKLV7KRVHURXJKQHVVYDULDWLRQVFRXOGEHGXHWRWKHVXFFHVVLYHIRUPDWLRQ DQGGHVWUXFWLRQRIDEXLOWXSHGJHZKLFKLVFKDUDFWHULVWLFRIWKH1LFNHOEDVHVXSHUDOOR\PDFKLQLQJ >@)XUWKHUPRUHRQWKHILJXUHEZHFDQVHHDGHSRVLWRI8GLPHWRQWKHFXWWLQJHGJHWRRO FRQILUPHGE\(QHUJ\'LVSHUVLYH6SHFWURPHWU\6''%58&.(5DQDO\VLV7KXVFXWWLQJSRZHULVD JRRGZD\WRGHWHFWVRPHDEQRUPDOFXWWLQJFRQGLWLRQVXFKDVEXLOWXSHGJHZKLFKFDXVHVDEQRUPDO FXWWLQJVFRUHV

)LJXUH  SUHVHQWV DQRWKHU H[DPSOH RI FRPSDULVRQ EHWZHHQ WZR VHQVRU VLJQDOV DQG WZR PLFURVWUXFWXUHDQRPDOLHV$ORQJWKHKROHZHREVHUYHWZRVLPLODULWLHV7KHILUVWRQHLVDFRUUHODWLRQ EHWZHHQWKHWKLFNQHVVRIDGLVWRUWHGOD\HUDQGWKHDSSHDUDQFHRIDUDSLGYDULDWLRQRIFXWWLQJSRZHU H[WUDFWHGIURPG\QDPRPHWHUWKLVREVHUYDWLRQFDQDOVREHPDGHZLWKWKHWRUTXHVLJQDO7KHVHFRQG %XLOWXSHGJHDQG 'HSRVLWRI8GLPHW D E 5DNH IDFH &OHDUDQFH IDFH )ODQNIDFH

9I

)]

0]

3

=

×

ω

+

×

RQH LV WKH WKLFNQHVV RI D KHDW DIIHFWHG OD\HU DW WKH VDPH WLPH DV WKH FXWWLQJ SRZHU LQFUHDVHV PHDVXUHGE\ERWKV\VWHPV)LJXUHVDDQGEVKRZWKHGLIIHUHQFHLQPLFURVWUXFWXUHDWDQGPP IURPWKHKROHHQWUDQFH,QILJXUHDZHREVHUYHDYHU\WKLQGLVWRUWHGOD\HUFRQWUDU\WRILJXUHE ZKHUHZHQRWLFHDQLPSRUWDQWZKLWHOD\HUDQGDVZHOODVDGLVWRUWHGOD\HU$PLFURKDUGQHVVILJXUH FPDSKDVEHHQGUDZQWRVKRZWKHLQIOXHQFHRIWKHPHFKDQLFDOHIIHFWLQWKHGHSWKRIWKHPDWHULDO 7KLVFRUUHODWLRQEHWZHHQSRZHUVLJQDODQGPLFURVWUXFWXUHPHWDOOXUJLFDOFKDQJHVZDVDOVRIRXQGLQ WKUHHRWKHUKROHVKLJKFXWWLQJVSHHGVRQILJXUHEXWZHFRXOGQRWGHWHUPLQHH[DFWO\WKHFDXVHRI WKHVXGGHQSRZHUFKDQJH   )LJXUH0LFURVWUXFWXUHDWDPPDQGEPPIURPWKHLQSXWRIWKHKROHF0LFURKDUGQHVV PDSDORQJWKHKROHDQGG3RZHUVLJQDOVFRPSDULVRQZLWKWKLFNQHVVRIDIIHFWHGOD\HUV 

'LVFXVVLRQ VXUIDFH LQWHJULW\ ± VSHFLILF FXWWLQJ FRHIILFLHQWV 0HWDOOXUJLFDO REVHUYDWLRQV GHILQH D

QHZFXWWLQJVSHHGGRPDLQILJXUHUHVSHFWLQJWKHVXUIDFHLQWHJULW\GHILQLWLRQ7KHRSWLPDOSRLQW GHILQHGLQSDUDJUDSKLVDWWKHOLPLWRIWKLVQHZGRPDLQ7KLVUHVXOWFRUURERUDWHVDQRWKHUVWXG\ >@ ZKHUH LW KDV EHHQ SURYHG WKDW VSHFLILF FXWWLQJ FRHIILFLHQWV DUH DEOH WR FKRRVH DQ RSWLPDO RSHUDWLQJ SRLQW UHVSHFWLQJ WKH VXUIDFH LQWHJULW\ GHILQLWLRQ 2Q WKH RWKHU KDQG WKH GDPDJH IUHH GRPDLQLVVPDOOHUWKDQWKHRQHGHILQHGE\&20PHWKRGRORJ\ILJXUH7KH&20GRPDLQZDV ZHOO GHILQHG WR DYRLG PHWDOOXUJLFDO PLFURVWUXFWXUH FKDQJHV EXW QRW IRU VPHDULQJ DQG FKDWWHUV ,W LQGLFDWHV WKDW SDUDPHWHUV WRRO ZHDU URXJKQHVV DQG KROH JHRPHWU\ FKRVHQ LQ DGGLWLRQ WR WKH VSHFLILFFXWWLQJIRUFHVWRHVWDEOLVK9FIZLQGRZDUHQRWDEOHWRGHWHUPLQHWKHGDPDJHIUHHGRPDLQ 7KLVHQKDQFHVWKDWDJOREDOYDOXHVXFKDVWRUTXHRUSRZHUWDNHQLQWRDFFRXQWIRU.FFDOFXOXVFDQQRW GHWHFW ORFDO DQRPDOLHV VXFK DV VPHDULQJ RU FKDWWHULQJ 6SHFLILF FXWWLQJ IRUFHV GR QRW WDNH LQWR DFFRXQWWKHWRSRORJ\RISRZHURUIRUFHVFXUYHV

&RQFOXVLRQ

,Q WKLV DUWLFOH ZH KDYH SUHVHQWHG WKH UHVXOWV IURP DQ H[SHULPHQWDO SURFHGXUH EDVHG RQ &20 PHWKRGRORJ\7ULDOVZHUHPRQLWRUHGZLWKDIRXUFRPSRQHQWVG\QDPRPHWHUDVSLQGOHSRZHUVHQVRU             'LVWDQFHIURPWKH VXUIDFHRIWKHKROHPP ' LVW DQ FH IUR P WK H HQ WU DQ FH RI WK H KR OH P P  0LFURKDUGQHVV+9V     +HDW PHFKDQLFDO DIIHFWHGOD\HU 'LVWRUWHGOD\HU 'LVWRUWHGOD\HU E G D F

DQGWKUHHDFFHOHURPHWHUV0HWDOOXUJLFDODQDO\VHVKDYHEHHQSHUIRUPHGRQKROHVSURGXFHGLQRUGHU WRLGHQWLI\DQGTXDQWLI\VXUIDFHLQWHJULW\DQRPDOLHV:HKDYHFRPSDUHGWKHFXWWLQJVSHHGGRPDLQ GHILQHGZLWKVSHFLILFFXWWLQJIRUFHVWRROZHDUURXJKQHVVDQGKROHJHRPHWU\ZLWKDFXWWLQJVSHHG GRPDLQGHILQHGUHVSHFWLQJWKHVXUIDFHLQWHJULW\GHILQLWLRQ

7KRVHH[SHULPHQWDWLRQVKDYHSHUPLWWHGWRXQGHUVWDQGWKHOLQNVEHWZHHQVSHFLILFFXWWLQJIRUFHVDQG VXUIDFH LQWHJULW\ DQG KDYH HQKDQFHG WKH ODFNV RI WKH &20 PHWKRGRORJ\ WRZDUGV ORFDO GHIHFWV SUHYHQWLRQ7KHVHKDYHDOVRSHUPLWWHGWRHVWDEOLVKFRUUHODWLRQVEHWZHHQVXUIDFHLQWHJULW\DQRPDOLHV REVHUYHG RQ WKH KROHV SURGXFHG DQG SURFHVV PRQLWRULQJ VLJQDOV UHFRUGHG GXULQJ WKH WULDOV 7KH URXJKQHVV DQG WKH PLFURVWUXFWXUH PHWDOOXUJLFDO FKDQJHV ZHUH FRUUHODWHG WR WKH FXWWLQJ SRZHU VLJQDOV

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XQGHUJUDQWDJUHHPHQWQXPEHU 5HIHUHQFHV >@ +73DQJ3$65HHG0LFURVWUXFWXUHHIIHFWVRQKLJKWHPSHUDWXUHIDWLJXHFUDFNLQLWLDWLRQDQG VKRUW FUDFN JURZWK LQ WXUELQH GLVF QLFNHOEDVH VXSHUDOOR\ 8GLPHW /L -RXUQDO RI 0DWHULDOV 6FLHQFHDQG(QJLQHHULQJ$±

>@ * 3HUULQ eWXGH PpWDOOXUJLTXH PpFDQLTXH HW WKHUPLTXH GH O¶LQWpJULWp GH VXUIDFH GHV SLqFHV SHUFpHV DX IRUHW KpOLFRwGDO GDQV O¶,QFRQHO 75  'pWHFWLRQ HW TXDQWLILFDWLRQ GHV DQRPDOLHV SDU 3URFHVV0RQLWRULQJ7KqVHGHGRFWRUDW(FROHGHV0LQHVGH3DULV

>@ $6KDUPDQ$$PDUDVLQJKHDQG.5LGJZD\7RROOLIHDQGVXUIDFHLQWHJULW\DVSHFWVZKHQ GULOOLQJDQGKROHPDNLQJLQ,QFRQHO-RXUQDORI0DWHULDOV3URFHVVLQJ7HFKQRORJ\ 

>@- .ZRQJ ' $[LQWH DQG 3 :LWKHUV7KHVHQVLWLYLW\RI1LEDVHGVXSHUDOOR\WRKROHPDNLQJ RSHUDWLRQV ,QIOXHQFH RI SURFHVVSDUDPHWHUV RQVXEVXUIDFHGDPDJHDQGUHVLGXDOVWUHVV-RXUQDORI 0DWHULDOV3URFHVVLQJ7HFKQRORJ\,Q3UHVV&RUUHFWHG3URRI

>@ (2 (]XJZX .H\ LPSURYHPHQWV LQ WKH PDFKLQLQJ RI GLIILFXOWWRFXW DHURVSDFH VXSHUDOOR\V ,QWHUQDWLRQDO-RXUQDORI7RROV 0DQXIDFWXUH

>@ $ 6KDUPDQ - +XJKHV DQG . 5LGJZD\ $Q DQDO\VLV RI WKH UHVLGXDO VWUHVVHV JHQHUDWHG LQ ,QFRQHO70ZKHQWXUQLQJ-RXUQDORI0DWHULDOV3URFHVVLQJ7HFKQRORJ\ >@ 0$1+,533URMHFW,QWHJUDWLQJ3URFHVV&RQWUROVZLWK0DQXIDFWXULQJWR3URGXFH+LJK,QWHJULW\ 5RWDWLQJ3DUWVIRU0RGHUQ*DV7XUELQHV)LQDO5HSRUW >@ '1RYRYLF5&'HZHV'.$VSLQZDOO:9RLFHDQG3%RZHQ7KHHIIHFWRIPDFKLQHG WRSRJUDSK\DQGLQWHJULW\RQIDWLJXHOLIH,QWHUQDWLRQDO-RXUQDORI0DFKLQH7RROVDQG0DQXIDFWXUH  >@ $)1251RUP1)(:RUNLQJ]RQHVRIFXWWLQJWRROV&RXSOHWRROPDWHULDO 

$GYDQFHVLQ6WUXFWXUDO$QDO\VLVRI$GYDQFHG0DWHULDOV 10.4028/www.scientific.net/AMR.112 /LQNV%HWZHHQ0DFKLQLQJ3DUDPHWHUVDQG6XUIDFH,QWHJULW\LQ'ULOOLQJ1L6XSHUDOOR\ 10.4028/www.scientific.net/AMR.112.171  '2,5HIHUHQFHV

[3] A. Sharman, A. Amarasinghe, and K. Ridgway. Tool life and surface integrity aspects when drilling and hole making in Inconel 718. Journal of Materials Processing Technology , 200, 424-432 (2008).

doi:10.1016/j.jmatprotec.2007.08.080

[5] E.O. Ezugwu. Key improvements in the machining of difficult-to-cut aerospace superalloys. nternational Journal of Tools & Manufacture 45, 1353-1367 (2005). doi:10.1016/j.ijmachtools.2005.02.003

[6] A. Sharman, J. Hughes, and K. Ridgway. An analysis of the residual stresses generated in Inconel 718(TM) when turning. Journal of Materials Processing Technology , 173, 359-367 (2006).

doi:10.1016/j.jmatprotec.2005.12.007

[8] D. Novovic, R. C. Dewes, D. K. Aspinwall, W. Voice, and P. Bowen. The effect of machined topography and integrity on fatigue life. International Journal of Machine Tools and Manufacture, 44, 125-134 (2004).