Flank wear assessment on discrete machining process behavior for Inconel 718

The characteristics of Inconel 718 alloy pose major challenges during the machining process. The following study aims to improve upon the product quality and machining productivity of the material by using polycrystalline cubic boron nitride (PcBN) tools and discrete machining. The use of PcBN tools offers benefits of sustainable and economical manufacturing. The experimental setup involved high-speed milling machine, a piezo-electric actuator and data acquisition software. This manuscript unveils a new flank wear assessment model that is applicable to a discrete machining process. The mathematical analysis develops a flank wear assessment for discrete machining and cutting speed parameters for Inconel 718. The cutting conditions were as follows: cutting speed, discrete machining frequency, feed per tooth and depth of cut. The tool-work interface process behaviors were evaluated in terms of the following: cutting forces, surface hardness, surface finish, surface texture, chip morphology and flank wear. The role of discrete machining allowed for a decrease in cutting forces and an improved surface finish and surface texture. The withdrawal of the tool allowed for the oil-air mist coolant to reach the heat-affected zone, thus reducing the severity in the heat-affected zone.