Study of saw-tooth chip in machining of Inconel 718 by metallographic technique

Abstract

The present research work aims to understand the chip formation mechanisms in Inconel 718 machining through metallographic technique. The influence of machining speed on shear band and chip shape have been analyzed. Characterization of the shear band has been conducted by analyzing the shear band thickness, strain, strain rate, stress and micro-hardness. Additionally, chip reduction coefficient parameters and chip segmentation ratio parameters have been analyzed to understand the type of chip formation at various machining speeds. The observations and analysis of the same indicated that the formation of the saw-tooth chip is due to high-strain localization within the chip and crack initiation at the free surface of the chip. Thinner shear bands are observed at higher machining speed (120 m/min), and thicker shear bands are observed at lower machining speed (40 m/min). The magnitude of chip segmentation parameters indicates that crack generation increases with increase in machining speed.