SUSU researchers presented the best ways to reduce of tool wear in the machining of superalloys

An overview study has been conducted by scientists from South Ural State University (SUSU) and foreign universities. The specialists have reviewed more than 200 sources of literature and conducted what parameters can extend tool life, specifically tool that machines superalloys. The research was published in the highly-rated journal CIRP Journal of Manufacturing Science and Technology (Q1).

Superalloys is a class of materials that are difficult to machine. Despite this, they are widely used in various engineering applications, such as mechanical engineering, aircraft construction, automotive and other industries. The reason is high temperature resistance and high strength properties that are shown by these alloys.

However, the cutting tool wears out intensively while machining, which causes a deterioration in the quality of the processed surface and is associated with such a concept as surface integrity, changing the surface topography, microstructure and mechanical properties. In the last study conducted by SUSU scientist Danil Pimenov and his foreign colleagues there has been comprehensive study of a large number of works on superalloys in order to investigate surface defects, surface roughness, and changes in microstructure and mechanical properties. Till now, very few studies in literature are available that cover all the tribological aspects during machining. The novel work covers in-depth analysis of it.

We have investigated tool wear and wear mechanisms such as abrasive, adhesive, oxidative, and diffusion and as a result of plastic deformation are considered in our study. We have reviewed over 200 sources of literature and out of them, the best findings were figured out in this work. The research is the product of various well-known world scientific schools,” tells senior lecturer of Institute of Engineering and Technology (SUSU) Danil Pimenov.

The researchers have considered possible options for reducing tool wear and thereby extending the tool life, as well as improving surface integrity, depending on the processing parameters, tool modification, and advanced cooling methods (machining without the use of a lubricating coolant or dry machining, machining using flow cooling, minimum amount of lubrication, cryogenic lubrication).

The research team has presented parameters that should be selected to reduce wear and improve surface integrity by optimization of cutting data. There has been concluded that tool tip texturing is a very promising technology and a future trend with the potential to reduce wear and improve surface integrity is quite prominent. Flood cooling machining protects the cutting edge of the tool well from intense wear and improves surface integrity. Hybrid use of minimum quantity machining and cryogenic lubrication can be beneficial for work process and environmental protection.

This review study is prepared by Dr. Murat Sarıkaya (Sinop University, Turkey), Dr. Munish Gupta and Professor Grzegorz Krolczyk (Opole University of Technology. Poland), Dr. Italo Tomaz (Waterford Institute of Technology, Ireland), senior lecturer Danil Pimenov (South Ural State University, Russia), Dr. Mustafa Kuntoglu (Selcuk University, Turkey), Dr. Navneet Khanna (Institute of Infrastructure Technology, India), Dr. Çagrı Yıldırım (Erciyes University, Turkey).

The results of the review article are beneficial for researchers and scientists who are working in the area of manufacturing, especially machining of superalloys.

Daria Tsymbaliuk, photo: Eugenii Zagoskin
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