We are metal specialists who provide a wide collection of products to customers all over the UK. In addition, we can offer assistance with other areas such as nickel alloy machining. As long serving professionals, those who work with us can trust our team to produce stellar results.
Nickel-based alloys have become very popular among multiple industries. This includes energy generation, automotive, and aerospace. The reason is their distinct and exceptional chemical and mechanical properties. The alloys display high tensile and yield strengths at low weights. Plus, they have excellent corrosion resistance in high temperature and acidic settings. Thanks to such advantageous characteristics, they have more of a presence in machine shops.
The other side of nickel alloys
However, we have to reveal that nickel alloys have another reputation. This is because they cause problems at the spindle. The metals can be problematic because they work harden easily. What’s more, the alloys can produce high temperatures when you machine them. They create gummy chips capable of welding onto cutting tools. The result is built-up edge. Thankfully, by possessing the right information, you can successfully perform nickel alloy machining.
As you machine nickel alloys, heat builds up. Chips have a habit of becoming stringy here, and end up sticking to a utensil’s cutting edge. This phenomenon is built-up edge, and it rounds the tool’s cutting edge. What you end up with is more friction and poor cuts. They contribute further to work hardening.
Something else built-up edge does is hasten tool wear. The rotational forces that are part of the cut increase. Since the cutting edge is now rounded from welded chips, you are forcing a blunt tool into the workpiece. The bluntness means the cutting motion transforms to ploughing instead of a shearing action. Rather than cutting through the metal, the tool pushes the material. It can mean you need to replace your tools much sooner than you should.
What causes built-up edge?
Now that we have had a look at the basics of built-up edge, we want to discuss what causes it. In addition, we will look into ways you can mitigate it in turning applications. This can help you to get better results with nickel alloy machining.
One cause is incorrect tooling choice. Built-up edge is usually caused by a turning utensil. This is one that lacks the right geometry for the material you are machining. Most significantly, when you machine a gummy material, you are better off with tooling that has very sharp cutting edges. The tooling also requires a polished flank and rake face, and free cutting geometry. What this will do is aid you in cutting quickly. At the same time, it will stop the material sticking to the cutting utensil.
Even if it is a turning tool with the right geometry, built-up edge is still possible. As your tool begins wearing out, its edge will deteriorate. As a consequence, the material will accumulate on the tool’s exterior. Thus, it is essential for you to examine a tool’s cutting edge after machining multiple components. You should do this randomly during the tool life too. It will assist you in discovering the root cause of failure modes by identifying them early. Plus, it will also ensure you are not wasting material by using old tools.
The last cause of built-up edge is insufficient heat generation. Too much heat can negatively influence a material. However, too little can lead to the tool being less efficient at chip removal. What you need to do is ensure you have the correct cutting parameters for nickel alloy machining, taking into account the feed and speed rates. You don’t want them to be causing excessive or too little heat.
How do we mitigate the issue?
We will finish by going over the ways to mitigate built-up edge in turning applications. First off, when choosing a tool favour sharp, free cutting geometries with extremely polished exteriors. Also, picking a tool with chipbreaker geometry will assist you with dividing chips. This shall help to remove them from the cutting surface and part.
You need to have confidence in your running parameters and application approach too. It is always vital to double-check that you have appropriate parameters for the turning applications. See to it that the coolant focuses on the cutting edge and improve the concentration amount as well.
Lastly, go for a coated insert. Coatings are engineered specifically for particular part materials. Also, they can stop common machining problems.
We are very reliable if you need nickel alloy machining
At Brindley Metals, we have become one of the most reliable suppliers of metals in the UK. It is the same for the specialist services we offer personally and arrange with third parties. Therefore, you can rely on us for almost any need.
So, if there is anything we can do for you in terms of metal supply, nickel alloy machining, and more, please let us know. We would be happy to work with you.