A study on the machining characteristics using plasma assisted machining of AISI 1045 steel and Inconel 718

• Published in: International journal of mechanical sciences Vol. 142-143; pp. 595 - 602
• Main Authors: Moon, Sung-Ho, Lee, Choon-Man
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.07.2018
• Subjects: Difficult-to-cut material; Laser assisted machining; Machining; Plasma; Plasma assisted machining; Laser assisted machining; Plasma; Difficult-to-cut material; Plasma assisted machining; Machining
• ISSN: 0020-7403; 1879-2162
• DOI: 10.1016/j.ijmecsci.2018.05.020

•In this study, PAM was developed and investigated and its performance compared with LAMill and CM.•The non-transferred type plasma torch used in this study and preheating experiments were performed to select the proper temperature.•Thermal analysis was performed to determine the proper preheating temperature and effective depth of cut of AISI 1045 steel and Inconel 718•The machining characteristics such as the cutting forces and surface roughness were measured based on the machining conditions. Difficult-to-cut materials such as titanium, Inconel and nickel alloys are being increasingly used in aerospace, automobile and medical equipment. However, these materials are difficult to machine using conventional machining (CM) methods, because of their superior material properties. New machining methods are being studied and developed for these materials. One of these machining methods, Thermal assisted machining (TAM,) applies a heat source to enhance the machinability of the materials. Laser assisted milling (LAMill) is a widely used type of TAM. In the LAMill process, a laser heat source softens the materials in front of the cutting tool. However, LAMill is expensive. A plasma heat source has been widely used for welding, melting, preheating, etc., and at a cost of about one tenth that of a laser heat source. But few studies on Plasma assisted machining (PAM) have been conducted. In this study, a PAM process was developed and investigated, and its performance compared with LAMill and CM. The proper preheating temperature and depth of cut (DOC) were determined by thermal analysis. Experiments were carried out with the PAM system on AISI 1045 steel and Inconel 718 using the determined preheating temperature and DOC. It was found that PAM reduced cutting force and improved the surface quality. [Display omitted]