Investigating the High-Speed Micro – Machinability of Aerospace Alloys

Abstract

Micro technologies including Micro-Machining have become essential part of the various
industries of modern era. Micro-machining is contributing to almost all fields of industries
like aerospace, automobiles, telecommunication, electronics, and medical sectors etc.
Therefore, 3D products in the industry require quality product and dimensional accuracy even
at micron level. Micro-milling, the most versatile micro-machining technique, has gained
importance in mass production of 3D components. Micro mechanical tools have great
potential for economical manufacturing of miniatured products from variety of materials, in
micro-milling operations. However, the previous research work shows some critical issues in
direct application knowledge of macro machining domain into micro domain with help of
simple analysis of parts dimensions. Thus, research work focuses on areas which require
scientific knowledge to be developed for further implementation at micro scale level to
improve the quality of final product.
Mechanical micro-milling of aerospace alloys remained focus of many researchers in past
because of having excellent mechanical properties, at extreme temperatures, that are suitable
for different sectors like aviation, automotive, nuclear, marine, and biomedical applications.
These are also considered a better option for applications where stresses need to be
minimised. Inconel alloy (Nickel-chromium based) and Monel alloy (Nickel-copper based)
being part of aerospace alloy, possesses greater strength and excellent corrosion resistance,
work hardening properties at elevated temperature. In aerospace sector, parts like discs, some
critical jet engine parts are also being manufactured with these alloys. Nevertheless, Nickle
alloys are hard to machine materials and have inherited poor machinability because of low
thermal conductivity. Low thermal conductivity results in significant increase of temperature
at the cutting zone which results in decreased life of cutting tool. Available research
knowledge of vital process parameters (feed per tooth, depth of cut, cutting speed, etc.) in
relation to micro-milling of Monel and Inconel alloys at high-speed micro-machining (HSM)
under various cooling environments and with multiple micro tool coatings present a research
gap. There is need to cover this gap by analysing effects of multiple cutting parameters with
wide range on responses at high-speed micro-machining of these alloys.

Date of Award	1 Jun 2024
Original language	English
Awarding Institution	National University of Sciences and Technology Pakistan