The critical problems faced during the machining process of heat resistant superalloys, (HRSA), is the concentration of heat in the cutting zone and the difficulty in dissipating it. The concentrated heat in the cutting zone has a negative influence on the tool life and surface quality of the machined surface, which in turn, contributes to higher manufacturing costs. This paper investigates improved heat dissipation from the cutting zone on the tool wear through surface features on the cutting tools. Firstly, the objective was to increase the available surface area in high temperature regions of the cutting tool. Secondly, multiple surface features were fabricated for the purpose of acting as channels in the rake face to create better access for the coolant to the proximity of the cutting edge. The purpose was thereby to improve the cooling of the cutting edge itself, which exhibits the highest temperature during machining. These modified inserts were experimentally investigated in face turning of Alloy 718 with high-pressure coolant. Overall results exhibited that surface featured inserts decreased flank wear, abrasion of the flank face, cutting edge deterioration and crater wear probably due to better heat dissipation from the cutting zone.
Keywords: Alloy 718; carbide insert; high-pressure coolant; machining; textured inserts; tool-chip contact area.