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Influence of Dry Cut and Tool Wear on Residual Stresses in High Speed Machining of Nickel-Based Superalloy

Machining induced residual stresses were investigated in Inconel 718 prepared by high speed turning under dry cut condition. The influence of cutting tool wear and the use of cutting fluid were studied. By x-ray diffraction measurements, characteristic residual stress distributions with tensile stresses in the top layer and compressive stresses in the layer below were found in all the investigated samples. The magnitude of surface tensile stresses and size of the tension as well as compression zones varied depending on the cutting condition. The application of cutting fluid for turning using new tool has a minor effect, giving a somewhat larger subsurface compressive zone but reducing the surface tensile stresses. Tool flank wear has shown a much stronger effect. While a flank wear of VBmax=0.15 mm enhanced mostly the surface tensile residual stresses, a severer wear of VBmax=0.3 mm greatly increased the thickness of the subsurface compression zone and at the same time resulted in strong stress anisotropy. Microstructural study by electron channelling contrast imaging shows that the observed influence of tool flank wear or cutting fluid on residual stresses are related to different contributions from increased plastic deformation and cutting heat, which changed with the cutting conditions.