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Surface Roughness and Tool Wear on Cryogenic Treated CBN Insert on Titanium and Inconel

718 Alloy Steel

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2015 IOP Conf. Ser.: Mater. Sci. Eng. 100 012058

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

Surface Roughness and Tool Wear on Cryogenic Treated

CBN Insert on Titanium and Inconel 718 Alloy Steel

S Thamizhmanii1, R Mohideen1, A M A Zaidi2 and S Hasan3

1
International College of Automotive,
Peramu Jaya, 26607, Pekan, Pahang, Malaysia.
2
Universiti Pertahanan Nasional Malaysia (UPNM),
Kem Sungai Besi, 57000, Kuala Lumpur, Malaysia.
3
University Tun Hussein Onn Malaysia,
Parit Raja, Batu Pahat, Malaysia.

Email: [email protected]

Abstract: Machining of materials by super hard tools like cubic boron nitride (cbn) and poly
cubic boron nitride (pcbn) is to reduce tool wear to obtain dimensional accuracy, smooth
surface and more number of parts per cutting edge. wear of tools is inevitable due to rubbing
action between work material and tool edge. however, the tool wear can be minimized by using
super hard tools by enhancing the strength of the cutting inserts. one such process is cryogenic
process. this process is used in all materials and cutting inserts which requires wear resistance.
the cryogenic process is executed under subzero temperature -186 celsius for longer period of
time in a closed chamber which contains liquid nitrogen. in this research, cbn inserts with
cryogenically treated was used to turn difficult to cut metals like titanium, inconel 718 etc. the
turning parameters used is different cutting speeds, feed rates and depth of cut. in this research,
titanium and inconel 718 material were used. the results obtained are surface roughness, flank
wear and crater wear. the surface roughness obtained on titanium was lower at high cutting
speed compared with inconel 718. the flank wear was low while turning titanium than inconel
718. crater wear is less on inconel 718 than titanium alloy. all the two materials produced saw
tooth chips.

1. Introduction
Machining of materials is recognized as removing unwanted materials by using different cutting
inserts with variable cutting parameters. Cryogenic process is treating the work materials and cutting
inserts at 186 Celsius. CBN and PCBN cutting tools are used to machine difficult to cut materials
like high strength alloy steels, stainless steel, Inconel 718, Titanium etc. Figure 1 shows generally
accepted cutting speeds in high speed machining of various materials. High speed turning is
recognized as a main manufacturing technology for higher productivity and throughput [1]. Barron [2]
performed abrasive wear tests on a wide variety of steels and concluded that metals which can exhibit
retained austenite at room temperature can have their wear resistance increased significantly, by
subjecting them to cryogenic treatment. Seah, Rahman [3] studied and found that cryogenic treated
tools improved wear resistance and overall tool lives of tungsten carbide tool inserts. Another studies
compared the performance of cryogenically treated and untreated tungsten inserts during high speed

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

milling of medium carbon steel. The cryogenically treated inserts exhibit better tool wear resistance
than untreated.

Figure 1. High-speed cutting ranges in machining of various materials [1].

2. Experimental Setup

2.1. Principle of deep cryogenic treatment

In this research, CBN inserts were cryogenically treated and the process is explained briefly.
Cryogenic expresses study and use of materials at very low temperature, below 186 Celsius. Liquid
Nitrogen (LN) is the most commonly used element in cryogenics. Nitrogen melts at -201.01 Celsius
and boils at 198.79 Celsius, it is the most abundant gas, composing about four fifths (78.03 %) by
volume of the atmosphere. It is colorless, odorless, tasteless and non-toxic gas. Deep cryogenic
treatment comprises of cooling the material over a period for few hours to the sub-zero range, holding
at this temperature for a long time and then returning to room temperature. The process is based on the
predetermined thermal cycle that involves cooling of the engineering components/materials in a
completely controlled cryogenic chamber. The material is slowly cooled to -196Celsius and soaked at
deep cryogenic temperature for 20 hours. The material is then allowed to return slowly to ambient
temperature. The complete cryogenic cycle would take up to 25-30 hours. Thermal control is
achieved by continuously monitoring inputs and regulating the flow of LN into the chamber and
alternating the heat. Precise program control takes the cycle through its three phases of descend, soak
and ascend. It is imperative that a slow descend is followed by soaking period for at least 24 hours at
-186 Celsius and raised to room temperature with a slow ascend. In this process, no dimensional
change and thermal crack occur. Strict computer control and precise processing profiles assure that
optimum results are achieved with no dimensional change or thermal shock. The system is relatively
simple and does not require large capital outlay.

2.2. Titanium (Ti-6Al-4V) alloy

Titanium alloy is an attractive material in many industries due to its unique and excellent combination
of strength to weight ratio and their resistance to corrosion. However, because of its low thermal
conductivity and high chemical reactivity, Ti-6Al-4V alloy is generally classified as a difficult to cut
material that can be characterized by low productivity and rapid tool wear rate even at conventional
cutting speeds. Table 1 and 2 show the mechanical and chemical properties of Titanium alloy and
Inconel 718 alloy respectively. The chemical and mechanical properties details were given along with
test certificates by the supplier.

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

2.3. Inconel 718

Inconel 718 is categorized as a nickel-based super alloy, which is extensively used in aerospace and
energy industry, specifically in the high temperature area of engine, because of their excellent
mechanical resistance to high temperature and corrosion. Many previous investigations have reported
that nickel-based super alloys are difficult to machine [4, 5] due to the following reasons: (1) high hot
hardness and strength causing deformation of the cutting tool; (2) the rapid work hardening causing
severe notch wear; (3) presence of primary carbide particles encouraging abrasion tool wear; (4) low
thermal diffusivity leading to extremely high local temperature on cutting edge; (5) welding of the
work piece to the tool cutting edge forming unstable built-up edge (BUE) which deteriorate machined
surface; and (6) possible chemical reactions accelerating tool wear. One of major issues in machining
of nickel-based super alloys is short tool life and thereby low productivity. Welding and adhesion of
work piece material onto the cutting tool frequently occur during machining causing severe notching
as well as alterations of the tool rake face due to the consequent pull-out tool material [6, 7]. Surface
quality is another important issue in the machining of nickel-based super alloys since critical
components, such as discs for jet engine, are often made of this material. The main problems reported
from previous investigations are surface tearing, cavities, cracking, metallurgical changes, plastic
deformation and formation of residual stresses in the case of machining with carbide cutting tools [5,
8]. Sadat and Reddy [9] found that an increase in cutting speed reduced surface damages by reducing
the cutting force due to an increase in cutting temperature and corresponding drop in work piece
strength. Ezugwu, Bonney [5] reported that the change of microstructure in subsurface when cutting
tool changed from a new tool to worn tool.

Table 1. Mechanical properties.

Tensile Yield
Grades % elongation
strength strength
Inconel 718 1240 MPa 1036 MPa 12
Titanium 147.8 KSI 138.5 KSI 19.2

Table 2. Chemical properties.

Alloying elements Titanium alloy Inconel 718

Carbon 0.030-0.031 0.08 max.
Manganese < 0.01 0.35 max.
Chromium, -- 17-21
Molybdenum < 0.01 2.80-3.30
Titanium alloy Balance 0.65-1.15
Nickel 50-55 --
Aluminum 6.51-6.57 0.20-0.80
Vanadium 4 - 4.07 --
Fe 0.17- 0.21 Balance
Silicon < 0.01 0.35 max.
Copper 0.01 0.30 max.
Cobalt -- 1.00 max.
Phosphorus -- 0.015 max
Sulfur -- 0.015 max.

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

Table 3. Operating parameters.

Cutting speed Feed rate
Depth of cut mm
m/min mm/rev
30 0.05 0.50, 0.75 & 1.00
40 0.10 0.50, 0.75 & 1.00
50 0.15 0.50, 0.75 & 1.00

3. Results and discussion

3.1. Surface roughness

Formation of the machined surface is closely associated with the reaction of the edge of cutting tool
and workpiece. Dhar N R [10] reported that the surface roughness was low with cryogenic treated
inserts in comparison with non-treated inserts at all cutting speeds. This has been more or less true for
all the work tool combinations undertaken in this research. Chen [11] stated that the surface
roughness would be low when the hardness of the material increased. Lateral plastic flow of the work
material in front of the cutting edge increased roughness of the machined surfaces.Thakur,
Ramamoorthy [12] turned Inconel 718 material by tungsten carbide tool and reported that the
roughness value decreased at high cutting speed but increased as the feed rate increased. This was due
to increased friction between work material and tool interface which eventually increases the
temperature in the cutting zone. The surface roughness values are higher when lower feed rate was
used, while the roughness values were smaller when higher feed rate was employed in the tests. This is
presumably, is due to ploughing action caused by smaller uncut chip thickness [13, 14]. Rougher
surface at small feed rate may associate with minimum chip thickness. Figure 2 (a to f) show graphical
representation of surface roughness against operating parameters as given in the Table 3. The surface
roughness obtained at cutting speed of 30, 40 and 50 m/min with at feed rate is low in turning
Titanium than Inconel 718 alloy steel even after 500 mm length turning. Smooth roughness obtained at
cutting speed of 50 m/min with feed rate 0.05 mm / rev. at 1 mm depth of cut. This was due to more
tool plough effect and plastic deformation produced low surface roughness.
Thakur, Ramamoorthy [12] turned Inconel 718 material by tungsten carbide tool and reported that
the roughness value decreased at high cutting speed but increased as the feed rate increased. This was
due to increased friction between work material and tool interface which eventually increases the
temperature in the cutting zone. The surface roughness values are higher when lower feed rate was
used, while the roughness values were smaller when higher feed rate was employed in the tests. This is
presumably, is due to ploughing action caused by smaller uncut chip thickness [13, 14]. Rougher
surface at small feed rate may associate with minimum chip thickness. Figure 2 (a to f) show graphical
representation of surface roughness against operating parameters as given in the table 3. The surface
roughness obtained at cutting speed of 30, 40 and 50 m/min with at feed rate is low in turning
Titanium than Inconel 718 alloy steel even after 500 mm length turning. Smooth roughness obtained at
cutting speed of 50 m/min with feed rate 0.05 mm / rev. at 1 mm depth of cut. This was due to more
tool plough effect and plastic deformation produced low surface roughness.

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

TIT-30-0.50 TIT-30-0.75 TIT-30-1.00 TIT- 40-0.50 TIT-40-0.75 TIT-40-1.00 ICN- 40-0.50

INC-30-0.50 ICN-30-0.75 INC-30-1.00 ICN- 40-0.75 ICN- 40-1.00
ROUGHNESS - MICRON

2 2

ROUGHNESS -
1.5 1.5

MICRON
1 1

0.5 0.5

0 0
100 200 300 400 500 100 200 300 400 500
LENGTH OF TURNING-FEED RATE -0.05 MM/REV LENGTH OF TURNING-FEED RATE -0.10-MM/REV

(a) (b)

TIT-50-0.50 TIT-50-0.75 TIT-50-1.00 INC-50-0.50 TIT-30-0.50 TIT-30-0.75 TIT-30-1.00 INC-30-0.50 INC-30-0.75 INC-30-1.00
INC-50-0.75 INC-50-1.00
ROUGHNESS - MICRON

180
1.45 160
140
ROUGHNESS -

1.25
120
MICRON

1.05 100
0.85 80
60
0.65
40
0.45 20
0.25 0
100 200 300 400 500 100 200 300 400 500
LENGTH OF TURNING-FEED RATE -0.15 MM/REV LENGTH OF TURNING-FEED RATE -0.05 MM/REV

(b) (d)
TIT-40-0.50 TIT-40-0.75 TIT-40-1.00 INC-40-0.50 INC-40-0.75 INC-40-1.00 TIT-50-0.50 TIT-50-0.75 TIT-50-1.00 INC-50-0.50 INC-50-0.75 INC-50-1.00
ROUGHNESS - MICRON
ROUGHNESS-MICRON

190 210
170 190
150 170
130 150
110 130
90 110
70 90
50 70
30 50
10 30
100 200 300 400 500 100 200 300 400 500
LENGTH OF TURNING-FEED RATE -0.10 MM/REV LENGTH OF TURNING-FEED RATE-0.15 MM/REV

(c) (f)

Figure 2. Graphs showing length of turning vs surface roughness: (a) 30 m/min cutting and feed rate
of -0.50 (b) 40 m/min cutting speed with 0.10 feed rate (c) 50 m/min cutting speed with 0.15 feed rate,
(d) DOC of 0.50 mm, (e) DOC of 0.75 mm and (f) DOC of 1.00.

3.2. Tool Flank Wear

Flank wear is formed on the flank side of the insert which is due to rubbing action of the insert and
machining surface. Figure 3 shows the various tool wear that is likely to occur as per ISO 3685 of
1993 [15]. The tools often fail rapidly due to non-uniform flank wear, chipping, depth of cut notching,
and plastic deformation of the cutting edge even at relatively low cutting. Low thermal conductivity
(11.4 W/m K), leading to high cutting temperature in cutting and high strength under high temperature
are responsible for its generally poor machinability [6]. In addition, the cutting forces generated are

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

also very high around double that found when cutting medium carbon steels [7]. This, in combination
with the relatively short chip contact length and high cutting temperature, induces very high stress
concentration on the area of tool / work piece interaction and leads to highly plastics deformation in
cutting edge and work piece material. Manu Dogra et al. [15] found that during the turning of
hardened AISI 4340 steel using CBN-TiN coated carbide and PCBN tools, result revealed that tool life
of CBN TiN coated carbide inserts was approximately 18-20 min per cutting edge, whereas PCBN
tools produced a tool life of 32 min. Flank wear is primarily attributed to rubbing of the tool along the
machined surfaces, causing abrasive diffusive and adhesive wear mechanisms and also high
temperature, which affect the tool material properties as well as work piece surface.

Figure 3. Various tool wear on a single point tool [15].

TIT-30-0.50 TIT-30-0.75 TIT-30-1.00 INC-30-0.50 TIT-40-0.50 TIT-40-0.75 TIT-40-1.00 INC-40-0.50

INC-30-0.75 INC-30-1.00 INC-40-0.75 INC-40-1.00

180 140
160
FLANK WEAR -

FLANK WEAR -

120
140 100
MICRON

MICRON

120
80
100
60
80
60 40
40 20
20 0
100 200 300 400 500 100 200 300 400 500

LENGTH OF TURNING-FEED RATE-0.05-MM/REV LENGTH OF TURNING - FEED RATE -0.10-MM/REV

(a) (b)
TIT-50-0.50 TIT-50-0.75 TIT-50-1.00 INC-50-0.50
INC-50.0.75 INC-50-1.00

120
FLANK WEAR -

100
MICRON

80
60
40
20
0
100 200 300 400 500
LENGTH OF TURNING-FEED RATE-0.15 MM/REV

(c)
Figure 4. Graph showing length of turning Vs flank wear (a) 30 m/min cutting and feed rate of -0.50
(b) 40 m/min cutting speed with 0.10 feed rate and (c) 50 m/min cutting speed with 0.15 feed rate.
In all the cutting speeds, flank wear was formed more at low feed rate of 0.05 mm/rev. Titanium
alloy steel. At 1 mm depth of cut in turning Inconel 718, the flank wear was low than 0.50 and 0.75
mm depth of cut. In this research, it was found that flank wear formation was high in Titanium than
Inconel 718 and shows that Titanium alloy is difficult to cut metal. Figure 4 (a to c) show graphical

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

representation of flank wear for all the three parameters. Figure 5 (a to i) shows SEM view on flank
wear by titanium alloy and more abrasion occurred than Inconel 718. Figure 6 show SEM view on
flank wear by Inconel 718 alloy steel which shows less flank wear.

(a) 30-0.05-0.50 (b) 30-0.05-0.75 (c) 30-0.05-1.00 (d) 40-0.10-0.50 (e) 40-0.10-0.75

(f) 40-0.10-1.00 (h) 50- 0.15-0.75 (i) 50-0.15-1.00

Figure 5. SEM view on flank wear on Titanium alloy.

(a) 30-0.05-0.50 (b) 30-0.05-0.75 (c) 30-0.05-1.00 (d) 40-0.10-0.50 (e) 40-0.10-0.75 (f) 40-0.10-1.00

(g) 50-0.15-0.50 (h) 50- 0.15-0.75 (i) 50-0.15-1.00

Figure 6. SEM view on crater wear while turning Titanium.

(a) 30-0.05-0.50 (b) 30-0.05-0.75 (c) 30-0.05-1.00 (d) 40-0.10-0.50 (e) 40-0.10-0.75

(f) 40-0.10-1.00 (g) 50-0.15-0.50 (h) 50- 0.15-0.75 (i) 50-0.15-1.00

Figure 7. SEM view on flank wear on Inconel 718 alloy.

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

3.3. Crater wear

Crater wear is formed at rake face of the tool. Figure 3 shows the various crater wear formation which
is represented by KT. The ISO 3685 of 1993 recommends the criterion of tool life due to crater wear
and can be calculated by using the formula as given below:
KT = 0.06 0.3 f (1)

where f is the feed rate and KT is the depth of crater.

Crater wear is dished out section which develops on the rake face of the tool. The formation of
crater wear occur little away from the cutting edges. In fact at low cutting speed, crater wear is usually
insignificant compared with flank wear in normal operations. There is no standard available for
maximum depth of the crater specification like flank wear. Deeper crater will lead to failure of the
cutting edge. When machining using CBN, PCBN inserts and other high strength inserts the
formation of wear take longer time. At high cutting speeds crater wear formation would be more
severe and depth of crater KT will be deeper. While turning difficult to cut materials crater wear was
more due to saw tooth chips. In turning Titanium alloy, the formation of crater wear was low than
Inconel 718. The saw tooth chips rougher and deeper crater formed. Figure 6, 7 and 8 show the crater
wear formed while turning Titanium and Inconel 718 respectively. More craters formed in turning
Titanium than Inconel 718.

(a) 30-0.05-0.50 (b) 30-0.05-0.75 (c) 30-0.05-1.00 (d) 40-0.10-0.50 (e) 40-0.10-0.75

(f ) 50-0.15-50 (g) 50-0.15-0.75 (h) 50-0.15-1.00

Figure 8. SEM view on crater wear on Inconel 718 alloy

4. Conclusions
The following conclusions were arrived in this research. They are:
Surface roughness obtained in turning Titanium alloy was low at cutting speed 50 m/min than
30 and 40 m/min than Inconel 718.
Surface roughness at depth of cut 1 mm is low than 0.50 and 0.75 mm in Titanium alloy than
Inconel 718.
Flank wear by Inconel 718 was low than Titanium. Flank wear at 1 mm depth of cut was low
than 0.50 and 0.75 mm.
Crater wear formed in turning Titanium alloy was un-uniform in wear. The crater wear by
Inconel 718 was less deep and small in magnitude of KT.

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3rd International Conference of Mechanical Engineering Research (ICMER 2015) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 100 (2015) 012058 doi:10.1088/1757-899X/100/1/012058

Cryogenic treated inserts performed very well by producing smooth surface roughness in
Titanium alloy than Inconel 718. On the other hand, flank wear was low in turning Inconel 718
than Titanium alloy.

Acknowledgements
The authors would like to thank International College of Automotive (ICAM) and Ministry of Higher
Education Malaysia for their financial support via Fundamental Research Grant Scheme (FRGS) Vot
0751.

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