Effect of Cutting Parameters on Tool Chipping Mechanism and Tool Wear Multi-Patterns in Face Milling Inconel 718

Tool wear behavior is mainly influenced by cutting parameters for a given tool–workpiece pair and cutting process. Rapid tool wear increases production costs and deteriorates machining quality in manufacturing industries. Inconel 718 is prone to severe tool wear in the milling process due to its high strength under elevated temperature and being prone to work hardening. The effects of cutting speed and feed rate on the tool chipping mechanism and tool wear multi-patterns in face milling Inconel 718 with cemented carbide tools are investigated in this research. Firstly, the face milling experiments of Inconel 718 were conducted with various cutting speeds and feed rates. The experimental results show that the tool wear morphology, especially the tool edge chipping on the flank face, is changed with the cutting parameters. Secondly, the tool chipping mechanism in the milling process is discussed. The effects of cutting speed and feed rate on the chipping and wear patterns of cutting tools are clarified. Finally, the ANOVA analysis is conducted to verify the effects of cutting parameters on cutting force, tool life, and tool edge chipping. This work provides an experimental basis for process parameter optimization to alleviate cutting tool wear in machining processes.