Ever since their introduction many years ago, heat resistant super alloys
(HRSA) have been difficult to machine.
But with developments in machinery, equipment and above all in tool materials
and new cutting processes, HRSA components now can be machined efficiently
and economically.
This a priority for aerospace, energy and medical industries as competitive and
environmental issues are increasingly important.
Although these alloys are ductile, their fatigue resistance, hardness and
toughness at high temperatures combine to develop a number of wear
mechanisms for cutting tools. The edge of a cutting tool is exposed to
considerable mechanical stress, strain and heat in machining these alloys.
High compressive and shearing forces attack the cutting edge while it is in its
most vulnerable condition, as the chip-flow temperature approaches the
temperature at which the cutting tool material begins to lose sufficient hardness.
Many HRSA materials also work harden readily. That gives rise to diffusion
wear, and usually leads to heavy burr formation. Work hardening also can make
subsequent operations more difficult.
This means that the cutting speed the factor largely responsible for the
amount of heat generated is limited and has to be kept well below that of
more common workpiece materials.
Whether the material is cast, forged or bar stock also affects HRSA
machinability and applications.
Then, a number of crucial tool and method factors must be considered. For
example: specific cutting forces for heat resistant super alloys can vary from
about 3,500 N/sq-m in the annealed/ solution-treated condition, to about 4,150
N/sq-m in an aged condition, and hardness can range from 30 to 48 HRC.
Notch wear, a mechanical type of wear in which the depth of cut sets the
workpiece material line.