Evaluation of the Influence of the Tool Set Overhang on the Tool Wear and Surface Quality in the Process of Finish Turning of the Inconel 718 Alloy

The work deals with the influence of the reach of the applied tool holder on the edge wear, dimensional accuracy and surface quality defined by the topography as well as the roughness of the machined surface. The research has been conducted on specimens made of Inconel 718 in the configuration of sleeves, within the scope of finish turning with constant cutting parameters, v_c = 85 m/min; f = 0.14 mm/rev; a_p = 0.2 mm. The material under machining has undergone heat treatment procedures such as solution treatment and precipitation hardening, resulting in a hardness of 45 ± 2 HRC. Two kinds of turning holders have been used with the reaches of 120 mm and 700 mm. The tools are intended for turning external and internal surfaces, respectively. The tests have been conducted using V-shaped cutting inserts manufactured by different producers, made of fine-grained carbide with coatings applied by the PVD (Physical Vapour Deposition) and CVD (Chemical Vapour Deposition) methods. The edge wear has been evaluated. The value of the achieved diameter dimensions has also been assessed in relation to the set ones, as well as the recorded values of surface roughness and the surface topography parameters have also been assessed. It has been determined that the quality of the manufactured surface evaluated by the 2D and 3D roughness parameters, as well as the dimensional quality are influenced by the kind of the applied tool holder. The influence is also visible considering the edge wear. The smallest values of the deviations from the nominal dimensions have been obtained for the coated inserts of the range of higher abrasion resistance (taking into account information from the producers). The obtained results show that in predicting the dimensional accuracy in the process of turning Inconel 718 alloy with long-overhang tools, one should consider the necessity of correction of the tool path. Taking into account the achieved surface roughness, it should be pointed out that not only the kind of the tool coating but also the character of its wear has a great influence, particularly, when a long cutting distance is required.