Deposition of Trace Coolant Elements on Flank Face ... - J-Stage

Deposition of Trace Coolant Elements on Flank Face inTurning of Inconel 718 Under High Pressure Conditions

Paper:


Toshiyuki Obikawa∗1,†, Zhenglong Fang∗2, Wataru Matsumoto∗2,Mamoru Hayashi∗2, Hideaki Hattori∗3, and Chikara Morigo∗4

∗1Tokyo Denki University5 Senju Asahi-cho, Adachi-ku, Tokyo 120-8551, Japan

†Corresponding author, E-mail: [email protected]∗2The University of Tokyo, Tokyo, Japan

∗3Idemitsu Kosan Co., Ltd., Ichihara, Japan∗4Tokupi Co., Ltd., Yao, Japan

[Received June 3, 2018; accepted October 9, 2018]

In this study, the coolant element deposition on theflank face of a coated tool in the turning of Inconel 718when the coolant jet was supplied from the tool flankside at coolant pressures from 1 to 20 MPa was in-vestigated. The flank wear-land was inspected afterthe cutting experiments using energy dispersive X-rayspectroscopy analysis to obtain the mappings of chem-ical elements contained in the workpiece, coating ma-terial, and coolant. It was found that coolant jetwith pressures higher than 5 MPa extended the toollife dramatically compared to flood cooling. In con-trast, increasing the coolant pressure beyond 5 MPayielded only marginal improvements of the tool life,as has been reported previously for very high coolantpressures. Trace chemical elements contained in thecoolant were mainly detected along the border of thetool-work contact area. The amounts of materials de-posited had a complicated relationship with the pres-sure, and a large amount of sodium, silicon, calcium,and phosphorus deposited at very high coolant pres-sures of 10 and 20 MPa. It was concluded that thesaturation of tool life extension at higher coolant pres-sures was ascribed to the thick deposited layer of amixture of compounds, such as calcium phosphate andsodium silicide, along the border, which preventedthe high-pressure coolant from penetrating into thetool/work contact area.

Keywords: high-pressure coolant, high-speed machin-ing, Inconel 718, tool wear, coolant element deposition

1. Introduction

Severe heat localization and the resulting thermo-mechanical loading cause rapid tool wear in the high-speed machining of nickel-base superalloys [1, 2]. Useof high-pressure coolants is one method for reducing thethermally induced wear, lowering the machining costs and

optimizing the surface quality and machining efficiency.These coolants typically extend the tool life significantlyby reducing the cutting temperature through efficient heattransfer from the tool to the coolant in the machining ofvarious difficult-to-machine materials [3–7]. However,the effect of very high-pressure coolant use is not straight-forward, and very high-pressures are often not the bestcooling conditions.

Ezugwu and Bonney [8] reported that the tool life wasshorter for coolant pressures of 15 and 20.3 MPa than for11 MPa in the turning of Inconel 718. Naves et al. [9]showed that the maximum width of flank wear had a min-imum value at a coolant pressure of 10 MPa and increasedfor larger coolant pressures in the turning of AISI 316austenitic stainless steel when using an emulsion-type cut-ting fluid at a 10% concentration. Da Silva et al. [10]showed that the maximum width of flank wear was greaterfor a coolant pressure of 20.1 MPa than for 10 MPaat a high cutting speed of 130 m/min in the turning ofTi-6Al-4V. Y. Ayed et al. [11] reported that the tool lifewas maximized at a coolant pressure of 10 MPa and de-creased at higher pressures in the machining of titaniumalloy Ti17 at lower cutting speeds of 50 and 75 m/min.At cutting speeds of 88 and 100 m/min, the tool liveswere similar for coolant pressures from 10 to 25 MPa.The above results indicate that the causal relationship be-tween coolant pressure and tool wear is complicated athigh pressures. Therefore, specific features of the toolface other than tool wear that indicate changes in the in-teractions between the tool and coolant would improvethe understanding of the effective use of high-pressurecoolants. In our previous paper [12], sodium was detectedon the flank face, which originated from the coolant in themachining of Inconel 718 using a high-pressure coolant,which had not been reported previously.

In this paper, the deposition of coolant elements on theflank face of a coated carbide insert, which is evidence ofthe interaction between the tool and coolant, was investi-gated after finish turning of Inconel 718 using a coolant atdifferent pressures. Scanning electron microscopy (SEM)

Int. J. of Automation Technology Vol.13 No.1, 2019 41

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Obikawa, T. et al.

Fig. 1. Tool holder with an L-nozzle.

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Spee

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Fig. 2. Coolant speed at nozzle versus coolant pressure.

and electron dispersive X-ray spectroscopy (EDS) wereused to inspect the adhered/deposited materials on thetool flank face. Wear of the coating layers and the ad-hesion/deposition of the work material and coolant ingre-dients on the flank face were clearly illustrated using theelemental mappings obtained by EDS analysis.

2. Experimental Methods

Turning experiments of the nickel-base superalloyInconel 718, with an average hardness of 510 HV, usinga high-pressure coolant were carried out using a DCLN(ISO)-type tool holder with a nozzle on the flank faceside. Fig. 1 shows an insert clamped on the tool holder.This nozzle is called an “L-nozzle” based on the shape ofthe exit orifice. The cutting conditions were as follows:depth of cut ap of 0.3 mm, feed rate f of 0.1 mm/rev, cut-ting speed Vc of 150 m/min, and coolant pressures Pc of1, 3, 5, 10, and 20 MPa. A regulator module was usedto change the coolant pressure from 1 to 20 MPa. A veryshort distance of 8 mm from the L-nozzle to the tool tipguaranteed that the coolant jet impinged on both the ma-jor and minor flank faces simultaneously and in signif-icant amounts. The flow rate of coolant q was measuredby means of a magnetic flow meter installed on the supplypipe. The mean coolant speed at the nozzle exit Vn [m/s]versus coolant pressure Pc [MPa] is shown in Fig. 2. Their

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Al B Ca Cu Fe K Li Na P Ba Mg Zn Si S

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Al B Ca Cu Fe K Li Na P Ba Mg Zn Si S

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Fig. 3. Trace elements in coolant.

relationship can be approximated by

Vn = aPbc . . . . . . . . . . . . . . . (1)

where the coefficient a and exponent b were determinedto be 23.75 and 0.42, respectively. In addition to thehigh-pressure coolant, a flood coolant (Pc = 0.13 MPa,q = 14.0 L/min) was also used for the cutting experimentsfor comparison.

The tool insert was a cemented carbide coated withthree layers of TiCN, Al2O3, and TiN. Its shape and ISOgrade were CNMG120408 and S01, respectively. Thequantities of trace elements in the emulsion-type coolantwith a 10% concentration used in this study were mea-sured by inductively coupled plasma mass spectrometry(ICP-MS) analysis. Fig. 3 shows the measured valuesof fourteen trace elements. Potassium, sodium, and zincwere found in the coolant at relatively high concentrationsof tens of ppm. The cutting fluid had been previouslyused. Thus, some chemical elements were observed inthe coolant after the cutting experiments. For example,the zinc observed was mainly due to the chemical reac-tions between the fatty acids of the coolant and the zinccoatings of galvanized pipes and tanks.

When the maximum width of the flank wear exceeded0.2 mm, which was assumed to be the critical value at theend of the tool life, the flank face was inspected by scan-ning electron microscopy and electron dispersive X-rayspectroscopy. Subsequently, the distribution of adheredmaterial was determined based on EDS mappings of theprimary elements of the work and coating materials andthe important trace elements of the coolant.

3. Results and Discussion

The tool lives for five coolant jet pressures and floodcooling are shown in Fig. 4. The high-pressure coolantsignificantly extended the tool life. The coolant jet at apressure of 5 MPa extended tool life by 268% comparedto the flood coolant. However, increasing the coolantpressure above 5 MPa did not improve the tool life fur-ther. As described above, when the coolant pressure in-creased to very high values, limits on the tool life ex-tension at a certain pressure [8–11] and saturation of toollife [13] have frequently been reported for the machining

42 Int. J. of Automation Technology Vol.13 No.1, 2019


( )

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life

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876543210

Fig. 4. Tool lives for coolant jets at five different pressuresand flood coolant.

Fig. 5. BSE images of flank faces after wear tests underdifferent cooling conditions.

of difficult-to-machine materials. It should be also notedthat many papers reported the superiority of high-pressurecoolants at only a specific pressure over flood coolant anddid not change the coolant pressure. Therefore, the resultshown in Fig. 4 is a typical example of machining usingvery high-pressure coolants.

Figure 5 shows the back-scattered electron (BSE) im-ages of the flank face at the end of the cutting test underdifferent cooling conditions. Note that the cutting lengthsof these six tools are quite different. Generally, a brighterregion in a BSE image represents heavier materials, whichin this case are nickel, chromium, and iron metals, whiledarker regions indicate lighter materials, such as nitrides,oxides, and carbon. It is clearly seen that a material otherthan the work material, which may be lighter than thework material, densely adhered below the region of flankwear when the coolant pressure was 10 or 15 MPa.

The secondary electron (SE) images of the borders ofthe flank wear-land under the six different cooling condi-

Fig. 6. SE images of borders of flank wear-lands for differ-ent cooling conditions.

tions are shown in Fig. 6. These micrographs indicate thatthe contact area between the tool flank face and machinedsurface can be divided into two or three zones of differ-ent surface features. These three zones are called the first,second, and third zones from the side of cutting edge, butthe third zone was not seen on the flank face sample whenusing the flood coolant. The width of each third zone isindicated using an arrow for different cooling conditionsin Fig. 6. EDS mappings of nickel as the primary elementof work material, aluminum and titanium as elements ofdifferent coating layers, and sodium as an important traceelement of the coolant, which were detected on the sameregions of the flank face as in Fig. 6, are shown in Fig. 7for the flood coolant and coolant jet at pressures of 1 and20 MPa.

As shown in Fig. 7, nickel was strongly and widely de-tected in the first zone just below the cutting edge. In thesecond zone, below the first zone of nickel, aluminum andtitanium were detected, and the signal intensity of alu-minum was higher than that of titanium because a coat-ing layer of TiCN was placed under a layer of alumina.Sodium was detected in the third zone when the coolantjet was used. The signal of sodium was very intensewhen the coolant pressure increased to 20 MPa. However,sodium was barely detected in the flood cooling sample,which is the reason that sodium deposition on the toolface has not been reported previously [3, 14–16] exceptin our previous report using a high pressure coolant jet of13 MPa [12]. On the coating surface without wear, alu-minum and titanium were detected because of a thin coat-ing layer of TiN, and the signal of aluminum was slightly


Obikawa, T. et al.

Fig. 7. Elemental mappings of Ni, Al, Ti, and Na on flank faces under different cooling conditions.

WC+Co

TiCN

Al2O3

TiN

Inconel 718

Chemical compounds of trace coolant elements

Tool matrix

Coating layers

Coated tool

Worn flank face

Flank face

Al2O3

TiN

TiN

Micrograph view

Fig. 8. Adhesion of work and coolant materials to flank face.

weaker than that of titanium, as seen in Fig. 7(a).Figure 8 schematically shows the surface conditions of

a worn tool flank face during EDS analysis. The aboveresults suggest that work material strongly adhered to thematrix of the coated carbide and a coating layer of TiCN.

Alumina, which has a weak affinity for the work material,showed excellent anti-adhesion properties to the work ma-terial because there was little adhesion of the work ma-terial to the second zone of the contact area, which wascovered by the coating layer of alumina. Materials ad-hered to the third zone may have mainly originated fromthe coolant ingredients. It is likely that the high-speed jetof coolant causing a high hydraulic pressure and high cut-ting temperature played a significant role in the promotionof the dense deposition of these materials. The speed ofthe coolant jet was higher than 80 m/s at a pressure of20 MPa. This speed is comparable to the minimum speedof ultrafine ceramic particles required for aerosol deposi-tion to form dense and hard ceramic coatings [17], e.g.,100 m/s for a lead-zirconate-titanate (PZT) coating. Ev-idence of sliding on the deposited materials in the thirdzone suggests that the deposited materials are not soft andfirmly adhered to the flank face.

As described above, the deposition of sodium in thethird zone increased with coolant pressure. However, itis difficult to quantitatively evaluate the amount depositedbecause the color bars on the left sides of the elementalmappings in Fig. 7 do not use the same scale. For this



Fig. 9. White dots indicating EDS count of sodium greaterthan ten for different cooling conditions.

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Fig. 10. Number of dots in mapping area of sodium fordifferent cooling conditions.

reason, only pixels in a display at which the number ofEDS counts was greater than ten during the mapping areindicated with white dots, and results obtained for sodiumunder six different cooling conditions are shown in Fig. 9.The number of white dots in the mapping area of sodiumfor different cooling conditions is shown in Fig. 10.

It is seen in Fig. 9 that the deposited sodium layer wasmuch thinner at a coolant pressure of Pc = 5 MPa thanthat at Pc = 10 and 20 MPa, although the widths of thedeposition bands were almost the same at Pc = 5, 10, and20 MPa, as shown in Figs. 6 and 9. According to Fig. 10,the total number of white dots sharply increased by a fac-tor of about 5 when the coolant pressure increased from 5to 10 and 20 MPa. Thus, the border of the contact areabetween the worn flank face and machined surface wasblocked by the thick material deposition. As a result,the lubrication environment of the contact area betweenthe worn flank face and machined surface for very high

Fig. 11. Plots of white dots in mapping area of calcium fordifferent cooling conditions.

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Fig. 12. Number of dots in mapping area of six elements fordifferent cooling conditions.

coolant pressures of 10 and 20 MPa may have changedsignificantly from that for coolant pressures up to 5 MPa.

Figure 11 shows the plots of white dots in the map-ping area of calcium for different cooling conditions. InFig. 12, the total number of white dots versus the coolantpressure is shown for calcium, silicon, phosphorus, potas-sium, zinc, and sulfur. It is seen that there were a large


Obikawa, T. et al.

EDS mapping area Cutting edgeCutting edge

Textured area

Fig. 13. Mappings of six chemical elements on the flankface of dot-type microtextured tool after machining usinghigh-pressure coolant at 13 MPa. The mapping area is shownon the micrograph of the tool flank face taken before cutting.

number of white dots of calcium for the flood coolant andcoolant jet at Pc = 1 MPa samples. However, calciumdoes not seem to have a large influence on the lubricationof the tool-work contact area because its deposition waswidespread over the flank wear at these conditions. Atvery high coolant pressures of 10 and 20 MPa, calciumshowed dense deposition at the border of tool-work con-tact area. Phosphorus and silicon showed similar deposi-tion characteristics to calcium, though the plots of whitedots in the mapping area are not shown for these elements.

Figures 9–12 suggest that the deposited materials inthe third zone were chemical compounds, such as a mix-ture of sodium silicate or calcium phosphate. Fig. 13shows the mappings of six elements on the flank faceof a dot-type microtextured tool with a groove depthof 20 µm after machining of Inconel 718 using a high-pressure coolant jet of 13 MPa. The microtextured toolwas used in previous work [12] but the elemental map-pings in this figure were measured for this paper. Thecutting speed of 120 m/min, feed rate of 0.1 mm/rev, anddepth of cut of 0.5 mm were comparable to those of thisstudy. It is clearly seen that sodium and silicon had the

same distribution in the third zone, and phosphorous andcalcium also had the same distribution, but not identicalto that of sodium and silicon. Thus, this figure wouldsupport the above suggestion of deposited chemical com-pounds. Note that it is typically difficult to definitivelydistinguish these two distributions because they have largeoverlapping areas.

Thick deposition of materials originating from thecoolant along the border of the tool-work contact areawould prevent the coolant from coming into the capillar-ies at the interface between the flank wear-land and ma-chined surface, which are the paths for coolant to pen-etrate deeper into the interface [18–20]. According toWilliams and Tabor [18], the heights of the capillaries areon the order of 1 µm. Therefore, the deposition in thethird zone seems sufficiently thick to block many capillar-ies when a coolant jet at very high pressures is used. As aresult, lubrication at the tool-work contact area is reduced,quite often resulting in a decrease in tool life. In thisstudy, the reduction in lubrication at the tool-work con-tact area could be compensated by the increase in coolingability when a very high-pressure coolant was used. Thismay be the reason that the tool life did not change signif-icantly for coolant pressures of 5, 10, and 20 MPa.

4. Conclusions

EDS analysis was used to investigate the ad-hered/deposited materials on the tool flank face of acoated tool and understand the marginal improvement ofthe tool life often reported in the very high-pressure range.As a result, the following conclusions were obtained.

1) High-speed turning experiments of Inconel 718 wereconducted using a coated tool and coolant jet at pres-sures up to 20 MPa. The high-pressure coolant ex-tended the tool life dramatically for coolant pressureup to 5 MPa but showed only marginal extensionsof tool life for coolant pressures of 10 and 20 MPa,as has been reported for very high-pressure coolantselsewhere.

2) Seven kinds of trace elements of the coolant were de-tected by EDS analysis. It was found that sodium,silicon, calcium, and phosphorous were depositedalong the border of tool-work contact area when thecoolant jet was used. When the coolant pressurewas 10 and 20 MPa, the deposited amounts of theseelements sharply increased.

3) The distributions of the above four elements sug-gested that the deposited materials along the borderwere contained in a mixture of compounds, such assodium silicate and calcium phosphate.

4) Thick material deposition along the border preventsthe coolant from penetrating deeper into the contactarea, resulting in a reduction in lubrication at thetool-work interface.



AcknowledgementsThe authors would like to thank Mitsubishi Material Corporationfor supporting this research.

References:[1] N. Suzuki, R. Enmei, Y. Hashimoto, E. Shamoto, and Y. Hatano,

“Tool Failure Mechanism in High-Speed Milling of Inconel 718 byUse of Ceramic Tools,” Int. J. Automation Technol., Vol.8, No.6,pp. 837-846, 2014.

[2] T. Obikawa and M. Yamaguchi, “Suppression of notch wear of awhisker reinforced ceramic tool in air-jet-assisted high-speed ma-chining of Inconel 718,” Precis. Eng., Vol.39, pp. 143-151, 2015.

[3] R. R. Srikant, P. N. Rao, V. V. Ramana, and M. Amrita, “Applicationof cutting fluids in machining of titanium alloys – a review,” Int. J.Adv. Manuf. Technol., Vol.91, pp. 2477-2498, 2017.

[4] A. Kramer, F. Klocke, H. Sangermann, and D. Lung, “Influence ofthe lubricoolant strategy on thermo-mechanical tool load,” CIRP J.Manuf. Sci. Technol., Vol.7, pp. 40-47, 2014.

[5] G. S. Su, Y. K. Guo, X. L. Song, and H. Tao, “Effects of high-pressure cutting fluid with different jetting paths on tool wear incutting compacted graphite iron,” Trib. Int., Vol.103, pp. 289-297,2016.

[6] L. Li, M. Wu, X. Liu, Y. Cheng, and Y. Yu, “Experimental studyof the wear behavior of PCBN inserts during cutting of GH4169superalloys under high-pressure cooling,” Int. J. Adv. Manuf. Tech-nol., Vol.95, pp. 1941-1951, 2018.

[7] Z. Fang and T. Obikawa, “Turning of Inconel 718 using inserts withcooling channels under high pressure jet coolant assistance,” J. Mat.Process. Technol., Vol.247, pp. 19-28, 2017.

[8] E. O. Ezugwu and J. Bonney, “Finish machining of nickel-baseInconel 718 alloy with coated carbide tool under conventional andhigh-pressure coolant supplies,” Trib. Trans., Vol.48, pp. 76-81,2005.

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[11] Y. Ayed, G. Germain, A. Ammar, and B. Furet, “Tool wear analy-sis and improvement of cutting conditions using the high-pressurewater-jet assistance when machining the Ti17 titanium alloy,” Pre-cision Engineering, Vol.42, pp. 294-301, 2015.

[12] Z. Fang and T. Obikawa, “Cooling performance of micro-textureat the tool flank face under high pressure jet coolant assistance,”Precis. Eng., Vol.49, pp. 41-51, 2017.

[13] E. O. Ezugwu, J. Bonney, D. A. Fadare, and W. F. Sales, “Machin-ing of nickel-base, Inconel 718, alloy with ceramic tools under fin-ishing conditions with various coolant supply pressures,” J. Mat.Process. Technol., Vols.162-163, pp. 609-614, 2005.

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Name:Toshiyuki Obikawa

Affiliation:Professor, Tokyo Denki University

Address:5 Senju Asahi-cho, Adachi-ku, Tokyo 120-8551, JapanBrief Biographical History:1980- Tokyo Institute of Technology2007- The University of Tokyo2017- Tokyo Denki UniversityMain Works:• “Metal Machining: Theory and Application,” Arnold, 2000.Membership in Academic Societies:• Japan Society for Precision Engineering (JSPE)• Japan Society of Mechanical Engineers (JSME)• Japan Society for Abrasive Technology (JSAT)

Name:Zhenglong Fang

Affiliation:Project Researcher (Post-Doctoral Fellow), The University of TokyoAddress:7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, JapanBrief Biographical History:2017- The University of TokyoMain Works:• Z. Fang and T. Obikawa, “Cooling performance of micro-texture at thetool flank face under high pressure jet coolant assistance,” PrecisionEngineering. Vol.49, pp. 41-51, 2017.• Z. Fang and T. Obikawa, “Turning of Inconel 718 using inserts withcooling channels under high pressure jet coolant assistance,” J. of MaterialsProcessing Technology, Vol.247, pp. 19-28, 2017.Membership in Academic Societies:• Japan Society for Precision Engineering (JSPE)

Name:Wataru Matsumoto

Affiliation:Tokyo Electron Ltd.Address:3-1 Akasaka 5-chome, Minato-ku, Tokyo 107-6325, Japan


Obikawa, T. et al.

Name:Mamoru Hayashi

Affiliation:Chief Engineer, Resonic Japan Ltd.Address:4259-3 Nagatsuta-cho, Midori-ku, Yokohama-shi, Kanagawa 226-8510,JapanMembership in Academic Societies:• Japan Society for Precision Engineering (JSPE)• Japan Society of Mechanical Engineers (JSME)

Name:Hideaki Hattori

Affiliation:Chief Engineer, Idemitsu Kosan Co., Ltd.

Address:1-1 Marunouchi 3-Chome, Chiyoda-ku, Tokyo 100-8321, JapanBrief Biographical History:2010- Idemitsu Kosan Co., Ltd.Main Works:• “Elucidation and Control of Tribology by Numerical Simulation andSurface Analysis,” Techno System Co., Ltd., 2018.Membership in Academic Societies:• Japanese Society of Tribologists (JAST)

Name:Chikara Morigo

Affiliation:President, Tokupi Co., Ltd.

Address:3-167 Otake, Yao, Osaka 581-0854, JapanBrief Biographical History:1974- Morigo Seiki Co., Ltd.2007- President, Tokupi Co., Ltd.Main Works:• Development of ultra high pressure coolant system• Cutting technology with ultra high pressure coolant up to 30 MPa• “State of the Art in High Speed Machining with High Pressure Coolant,”Seisan Kenkyu, Vol.67, pp. 607-612, 2015.Membership in Academic Societies:• Yao Technical Committee of Burr Technology• Japan Society for Precision Engineering (JSPE)• Japan Society of Mechanical Engineers (JSME)• Japan Society for Abrasive Technology (JSAT)


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