As new materials come into existence such as Multi component alloys, custom made application oriented alloys-Nickel alloys. There are lots of unknown about the machinabaility of these materials. Is it justified to leave it casting for final shape and tolerance? Or does machining have to take place for an optimum finish and dimension accuracy?
The actual european criteria is to use the better tool material at the biggest possible cutting speed. This idea turn around that the tools represents only 3% over the production costs.
Normally the 6 quality group grades gives by iso is an excelent reference.
Two things more. The iso standard is 513:2004 and the grade for ni alloys is the N grade.
Dear Ashwin,
Your problem is genuine specially when the hardness and other mechanical properties of the work material are better than those of the tools being used. In such cases you have to go to Advanced Machining Processes (say, EDM, LBM, ECM, etc.) . For finishing, or even nano-finishing you have to select a process very judiciously else the finishing cost also may go very high.
With best wishes.
VKJain
It depends on the application! for structural components used in engines, the casting would not be adequate. so, in this case the machining still the suitable process. in the last decades, many research works have been done on the machinability of Ni based super alloys which can be a good reference for the initial cutting conditions selection. for example, uncoated carbide inserts can be very efficient for machining Inconal alloys even at 40 HRC hardness. Moreover, some new version of PCBN tools can be also be used to get better surface finish.
Yes, Dr. Walid Jomaa is correct. As long as conventional cutting is feasible, it should be done because it is cheaper and faster.
Thanks a lot everyone for your opinions. This is has given me an idea how to approach these materials.
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