Investigation of machinability of Waspaloy super alloy with milling method using different cooling techniques

In this study, the effects of the cutting parameters and the cooling methods on the machinability in the milling of nickel based Waspaloy were investigated. In the first step, 16 experiments were carried out the input parameters of oil type, flow rate, milling direction, spray distance and nozzle type were selected while keeping the cutting speed, feed, depth of cut and cutting tool constant. As a result of these experiments, the minimum quantity of lubrication parameters which use for the main experiments with vegetable oil, 100 ml/h flow rate, up milling, 25 mm spray distance and 1 nozzle were determined. For the main experiments, Uncoated, PVD (TiAlN) and CVD (TiCN+Al2O3+TiN) coated carbide was selected as the first group cutting tool materials. As the cutting parameters; cutting speed (30, 45, 60 m/min), feed rate (0.10, 0.15, 0.20 mm/rev) and cooling method were selected. Alumina, whiskers and sialon based ceramic insert were determined as the second group of cutting tools. As a cutting parameter; cutting speed (500, 600, 700 m/min), feed rate (0.02, 0.04, 0.06 mm/rev) and cooling method were selected. The effects of cutting parameters on cutting force, surface roughness and tool life/wear were investigated by Variance analysis (ANOVA) was performed for values which obtained as a result of the experiments. As a result of the study, prediction equations are created through regression analysis and prediction models are obtained for similar studies that are thought to be done in the future. As a result; the highest tool life for carbide inserts was achieved with wet machining, PVD (TiAlN) coated carbide, 30 m/min cutting speed and 0.1 mm/rev feed rate. The lowest cutting force value was obtained by wet machining, PVD (TiAlN) coated tip, 45 m/min cutting speed and 0.1 mm/rev feed rate. The lowest surface roughness value was obtained by wet machining, PVD (TiAlN) coated carbide, 45 m/min cutting speed and 0.1 mm/rev feed rate. The lowest wear value for ceramic tools was obtained with Minimum Quantity Lubrication (MQL), sialon insert, 700 m/min cutting speed and 0.06 mm/rev feed rate. The lowest cutting force value obtained with MQL, sialon insert, cutting speed of 600 m/min and 0.02 mm/rev feed rate. The lowest surface roughness value was given with MQL, sialon insert, cutting speed of 700 m/min and 0.02 mm/rev feed rate parameters.