Minor cutting edge–workpiece interactions in drilling of an advanced nickel-based superalloy |
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| Authors: | J. Kwong D.A. Axinte P.J. Withers M.C. Hardy |
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| Affiliation: | 1. School of Mechanical, Materials and Manufacturing Engineering, The University of Nottingham, Nottingham NG7 2RD, UK;2. School of Materials, The University of Manchester, Grosvenor Street, M1 7HS, UK;3. Rolls-Royce plc, P.O. Box 31, Derby DE24 8BJ, UK;1. Opole University of Technology, Miko?ajczyka 5 Str., 45-271 Opole, Poland;2. Rzeszów University of Technology, ?wirki i Wigury 4 Str., 35-001 Rzeszów, Poland;3. Pratt & Whitney Poland, Rzeszów, Hetmańska 120A Str., 35-078 Rzeszów, Poland;1. Fraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh J_LEAPT), Department of Chemical, Materials and Industrial Production Engineering University of Naples Federico II, Piazzale Tecchio 80, 80125 Naples, Italy;2. D Y Patil College of Engineering and Technology, Kolhapur, 416006, India;3. D Y Patil Polytechnic, Kolhapur, 416006, India;1. Machining Research Group, School of Mechanical Engineering, University of Birmingham, Edgbaston, Birmingham, UK;2. Manufacturing Technology, Rolls-Royce plc, Derby, UK;3. Turbines, Rolls-Royce plc, Derby, UK;1. Institute for Sustainable Manufacturing (ISM), University of Kentucky, Lexington, KY 40506, USA;2. Department of Mechanical Engineering, Faculty of Technology, Marmara University, Goztepe Campus, Kadikoy, 34722, Istanbul, Turkey |
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| Abstract: | Drilling is one of the key machining operations for manufacturing safety critical components that must comply with strict surface quality standards. The influence of major flank wear of drilling tools on workpiece surface quality has been well established; however, similar information concerning minor cutting edge is currently missing from literature. This paper presents a comprehensive analysis and discussions of the influence of the drill's minor cutting edge to workpiece surface integrity and residual stress distribution for RR1000, a newly developed nickel-based superalloy. These effects are critical to the acceptance of this new material in relation to tool geometry and machining strategies. The thickness of material drag in the hoop direction has been found to be the highest at the top and the least at the bottom of the hole, which is directly related to the contact duration between the minor cutting edge and workpiece surfaces; moreover this difference increased at higher levels of wear of the minor cutting edge. On-line process monitoring techniques have been employed to further understand the material drag phenomena, including feed force, torque and acoustic emission. Compressive axial and tensile hoop stresses at the surface of the holes have been measured as a function of depth and correlated both with metallurgical analysis of drilled surfaces and the process monitoring signals. It was found that the increased material drag associated with a worn tool resulted in compressive hoop surface residual stresses near the entrance hole in correspondence with trends in the processed acoustic emission signal. This work suggests that material drag increases with the duration of the minor cutting edge–workpiece interaction such that plastic deformation is the greatest near the drill entrance holes and that process monitoring of the degree of material drag in hoop direction can be practicable. |
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