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Analyzing the effect of cutting parameters on surface roughness and tool wear when
machining nickel based hastelloy 276

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2011 IOP Conf. Ser.: Mater. Sci. Eng. 17 012043
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CAMAN
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

IOP Publishing
doi:10.1088/1757-899X/17/1/012043

Analyzing the effect of cutting parameters on surface

roughness and tool wear when machining nickel based
hastelloy 276.
Basim A. Khidhir1 and Bashir Mohamed1
Department of Mechanical Engineering, College of Engineering, University Tenaga
Nasional, 43009 Kajang, Selangor, Malaysia
Email: [email protected]
Abstract Machining parameters has an important factor on tool wear and surface finish, for
that the manufacturers need to obtain optimal operating parameters with a minimum set of
experiments as well as minimizing the simulations in order to reduce machining set up costs.
The cutting speed is one of the most important cutting parameter to evaluate, it clearly most
influences on one hand, tool life, tool stability, and cutting process quality, and on the other
hand controls production flow. Due to more demanding manufacturing systems, the
requirements for reliable technological information have increased. For a reliable analysis in
cutting, the cutting zone (tip insertworkpiecechip system) as the mechanics of cutting in this
area are very complicated, the chip is formed in the shear plane (entrance the shear zone) and
is shape in the sliding plane. The temperature contributed in the primary shear, chamfer and
sticking, sliding zones are expressed as a function of unknown shear angle on the rake face
and temperature modified flow stress in each zone. The experiments were carried out on a
CNC lathe and surface finish and tool tip wear are measured in process. Machining
experiments are conducted. Reasonable agreement is observed under turning with high depth
of cut. Results of this research help to guide the design of new cutting tool materials and the
studies on evaluation of machining parameters to further advance the productivity of nickel
based alloy Hastelloy - 276 machining.

1. Introduction
Increasing the productivity and the quality of the machined parts are the main challenges of
manufacturing industry. Modern cutting tools allow cutting at high speeds, thus increasing the volume
of chips removed per unit time and this objective requires better management of the machining system
corresponding to cutting tool-machine tool-workpiece combination to go towards more rapid metal
removal rate. Exploring higher cutting speed depends to a greater extend on the cutting tool materials
[1]. General information on operating parameters employed when turning Nickel based alloys are
available in both academic [2-5] and industrial literatures [6, 7]. From the very beginning, development
of an adequate predictive theory of the process was of a major concern for all researchers. In relation to
machining operations with defined cutting edges, workpiece surface integrity aspects when turning
Inconel 718 with coated carbide cutting tools [8, 9]. Due to their high temperature strength and high
corrosion resistance, nickel based alloys are used for engines for commercial and military aircraft and
space engines. Is considered by machinists one of the most challenging areas. This is due to a complex
of material properties [10,11] namely: low thermal conductivity leading to increased temperatures at
the tool point rake face, work-hardening tendency during machining, high thermal affinity to tool
Published under licence by IOP Publishing Ltd

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IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

IOP Publishing
doi:10.1088/1757-899X/17/1/012043

materials resulting in welding-adhesion of workpiece material to the cutting edge, presence of hard
abrasive particles (e.g. carbides, oxides) resulting in intense tool wear [12]. The heat generated during a
cutting operation is the summation of plastic deformation involved in chip formation and the friction
between tool and workpiece and between the tool and the chip [13]. Metallurgical changes that have
improved superalloys making the metal stronger, tougher or more resistant to oxidation or corrosion,
have also made these metals more difficult to machine. For the nickel based superalloys, high
temperature characteristics translate directly to machining challenges. The combination of high cutting
force and high temperature when machining these materials leads to edge breakdown of the tool
through chipping or deformation. In addition, for the majority of these metals, work hardening takes
place rapidly. A hardened surface created during machining can result in depth-of-cut-line notching of
the tool and may also compromise the fatigue strength and geometric accuracy of the part [14]. Many
nickel alloys are age hardenable, meaning that the hardness of the alloy increases dramatically upon
heat treatment. As second phase particles form, the alloy becomes stronger and more abrasive, thus
more difficult to machine [15]. The geometry of the tool plays a big part in controlling wear. The
geometry of the cutting tool must allow for chip removal in order to take the heat out with the chip.
Tool geometry should allow for smoother cutting and less vibration and better chip evacuation. In
addition, higher rpm and feed rates with shallow depth-of-cut are typically required to maintain chip
flow and heat [16-17]. This study intend to investigate the effect of insert geometries on cutting
performance in terms of tool life and tool wear when machining of nickel-based alloys - 276.
2. Experimental procedure
The machining tests were performed by single point. A CNC turning machine OKUMA CNC turning
machine supported with Spindle Drive motor 11 KW and 6000 Rpm maximum speed. Z- axis Simens
AC Servo motor 8 Nm and X- axis Simens motor 6 Nm as shown in Figure 1.

Figure 1. CNC machine used in experiments

The workpiece of nickel based Hastelloy 276 specimens were 300 mm long and 50 mm diameter.
The chemical compositions of the workpiece materials as [Ni:57%; Co:1.62%; Cr:15.44%;
Mo:15.34%; Fe:5.43%; W3.67%; V:0.41%; Mn:0.52%; C:0.004%; Others (Si<0.02%; P-0.005%;
S<0.01%)] and the physical compositions are given in table 1.

Table 1. Physical properties

Electrical
Resistively

Density
3

8.89 g/cm 1.3 m

Dynamic
Thermal
modulus of
conductivity
elasticity

Specific
heat

229 MPa

427 J/Kg.K

10.2 W/m.K

Ceramic insert tools used for machining nickel based Hastelloy C-276 as shown in Table 2.
2

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IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

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doi:10.1088/1757-899X/17/1/012043

Table 2. Insert tools and holders used during experiments.

No
3

Insert material

Tool insert code

RNGN 120400E

Tool holder code

CRSNR 2525M 12-ID

4
5

Ceramic

SNGN 120412E
CNGN 120408 E

SNGN 120412E
CCLNR 2525M 12-4

Surface roughness measurement was carried out on the machined surfaces using a Hand held
Roughness Tester TR200 instrument. Three measurements were made on the each surface. The worn
cutting tools were also examined under a Philips XL 30 ESEM type scanning electron microscope
(SEM).

2.1. Design of experiment

Response surface methodology (RSM) is used to find a combination of factors which gives the optimal
response. RSM is actually a collection of mathematical and statistical technique that is useful for the
modeling and analysis of problems in which a response of interest is influenced by several variables
and the objectives is to optimize the response [18]. There are essentially two main types of designs
experiments which are based on response surface analysis as follows:
1. Central Composite Design (CCD).
2. Box-Behnken Design (BBD).
Both of these methodologies require a quadratic relationship between the experimental factor and the
responses. In this paper the BBD has been chosen as shown in Figure 2.

Figure 2. The 3N full factorial

The levels of independent variables and coding identifications used in this design are presented in
Table 3.
Table 3. Variables coding identifications

Code

-1

+1

Cutting speed (m/min)

150

200

250

Feed rate (mm/rev)

0.15

0.2

0.25

Depth of cut (mm)

0.5

1.5

Nose radius (deg.)

0.8

1.2

12

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IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

IOP Publishing
doi:10.1088/1757-899X/17/1/012043

Table 5 shows the experimental conditions and results obtained using ceramic inserts. All of the
turning tests were run dry. Box- Behnken Design is normally used when performing non-sequential
experiments. That is, performing the experiment only once. These designs allow efficient estimation of
the firstorder coefficients. Because Box-Behnken Design has fewer design points, they are less
expensive to run than central composite designs with the same number of factors. Box-Behnken Design
do not have axial points, thus can be sure that all design points fall within the safe operating. BoxBehnken Design also ensures that all factors are never set at their high levels simultaneously [19].
Figure 3 shows the 3N full factors Box-Behnken. Preliminary tests were carried out to find the suitable
cutting speed V, feed rate f, depth of cut d and approach angle K as shown in Table 4. Every one passes
(one pass is equal to 20mm), the cutting test was stopped. The same experiment has been repeated for 3
times to get more accurate result.
Table 4. Experimental conditions and results obtained using ceramic inserts

Run
order

Cutting
speed,
V (m/min)

Feed rate, f
(mm/rev)

Depth of
cut, d (mm)

Nose radius, r
(mm)

Exp. Surf.
Rogh. Ra
(um)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

0
1
0
0
1
1
0
0
-1
-1
0
0
1
0
0
1
1
-1
0
0
0
0
-1
0
-1

-1
1
0
-1
0
0
0
1
0
0
-1
1
0
1
1
-1
0
-1
-1
0
0
0
0
0
0

0
0
-1
-1
0
-1
-1
0
1
0
0
-1
1
1
0
0
0
0
1
0
1
1
-1
0
0

-1
0
-1
0
1
0
1
-1
0
1
1
0
0
0
1
0
-1
0
0
0
-1
1
0
0
-1

0,184
0,25
0,382
0,555
1,045
0,8
1,04
0,378
2,373
1,404
1,162
1,349
1,436
1,771
1,076
0,844
0,466
0,423
5,216
0,78
3,532
1,064
1,327
0,78
2,333

26

0,78

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IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

IOP Publishing
doi:10.1088/1757-899X/17/1/012043

2.2. Regression model

The surface roughness (Linear + interaction) regression model is:

SR = - 27,3 + 0,105 V + 141 f + 9,16 d - 0,069 r - 0,536 Vf- 0,0023 Vd - 0,00119 Vr - 38,2 fd + 0,52 fr + 0,177 dr


---------------(1)

Where SR is Surface roughness (Ra um), V is cutting speed (m/min), f is feed rate (mm/rev), d is depth
of cut (mm), r is nose radius (mm).

Table 5. Analysis of Variance

Source DF Seq SS Adj SS Adj MSFP
Regression 10 23 23.4096 2.34096 3.24 0.018




Linear 4 11 10.8013 2.70033 3.74 0.025




Interaction 6 11 11.9106 1.98511 2.75 0.050
Residual Error 16 11 11.5659 0.72287

The p-value for lack of fit is 0.095 suggesting that this model adequately fits the data.

Table 6. P- value for the terms of surface roughness Ra

Term T
P
Constant 7.021 0.000
V

-1.852 0.083
f

-0.073 0.943
d

3.291 0.005
r

-0.718 0.483
V * f

-2.995 0.009
V* d

-0.195 0.848
V* r

-0.988 0.338
f *d

-2.637 0.018
f * r
0.341 0.737
d * r
1.548 0.141

Table 6 gives the results of the ANOVA of surface roughness of machined specimen. It can be seen
from table 7, that the most significant parameters influencing the surface roughness is the cutting
speed, see the main effects plots for SN ratio in Fig. 3. It is known from the fundamental theory of
machining that the feed rate and nose radius play an important role in roughness of the machined
surface when the cutting edge is sharp [20]. However, when the cutting edge is not sharp or modified
as in this case, the cutting edge is chamfered, then other factors come into effect and influence the
surface roughness. It is observed that the surface roughness is higher (poor surface finish) at the lower
cutting speed. The surface roughness is lower (good surface finish) as the cutting speed increases to its
highest level. Thus, at higher MRR, the volume of the accumulated material is more, thereby suppress
the effect of cutting edge radius and feed rate more effectively. Consequently, the surface finish is
better [21]. Generally, the increase of cutting speed will improve of the surface finish while increasing
depth of cut will increase the value of surface roughness to become larger. On the other hand, the
changing in feed rate will take no effect on surface roughness as shown in Figure 3.

CAMAN
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

IOP Publishing
doi:10.1088/1757-899X/17/1/012043

Figure 3. Main Effects Plot (data means) for Exp. surface roughness Ra (um)

The proposed linear equation is valid only for cutting ceramic tools with a (-6) rake angle within the
cutting conditions range used in the experimentation. Figure 4 shows the plot of experimental surface
roughness versus predicted surface roughness from eq. (1) it is clear that the predicted values are in
good agreement with the experimental readings. This indicates that the obtained linear model is useful
to be the empirical modal for selecting cutting speed values.

Surface
roughness (m)

(No.

of Exp.)

Figure 4. Prediction of cutting force with experimental cutting force.

3. Results and discussions
Generally, cutting tool materials are exposed to high mechanical stresses and thermal disturbances
when machining nickel based Hastelloy C-276 resulting in low surface roughness, cutting tool wear
and short tool life. Results showed That the most dependent parameter affected the surface finish is
cutting speed followed by depth of cut and the interaction of cutting speed versus depth of cut, nose
radius and feed rate as shown in Figures 5, 6 and 7 respectively.

CAMAN
IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

IOP Publishing
doi:10.1088/1757-899X/17/1/012043

Surface roughness
(m)

Cutting speed
(m/min)

Depth of cut (mm)

Figure 5. Surface roughness in the cutting speeds - depth of cut plane.

Surface roughness
(m)

Cutting speed
(m/min)

Nose radius (mm)

Figure 6. Surface roughness in the cutting speeds - nose radius plane.

Surface roughness
(m)

Feed rate (mm/rev)

Cutting speed
(m/min)

Figure 7. Surface roughness in the cutting speeds - feed rates plane.

Different type of tool wears appears during experiments as flank wear and chipping as shown in
Figures 8 and 9. Built up edge (BUE) was the factor appears during experiments as shown in Figures
10.

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IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

IOP Publishing
doi:10.1088/1757-899X/17/1/012043

Figure 8. Flank wear in the cutting speed feed rate plane for 0.5 mm depth of cut and 0.8 mm nose
radius.

Figure 9. Chipping wear in the cutting speed feed rate plane for 1 mm depth of cut and 1.2 mm nose
radius.

Figure 10. BUE in the cutting speed depth of cut plane for 0.15 mm feed rate and 0.8 mm nose
radius.

Tool wear type while cutting the Hastelloy - 276 is chipping wear at the line depth of cut due to high
thermal, high work hardness, high strength of the work-piece and abrasive particles. Furthermore; flank
wear, chipping and severe damages are the causes of tool wear.
The inserts were tested by cutting Hastelloy - 276 under different cutting parameters as listed in Table
3. For each experiment, Reference flank wear value VBB = 0.3 mm is chosen as wear criterion
according to International Standard Organization. A cutting tool was rejected and further machining
was stopped based on one or a combination of the following rejection criteria in relation to ISO
Standard 3685 for tool life testing:
8

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IOP Conf. Series: Materials Science and Engineering 17 (2011) 012043

IOP Publishing
doi:10.1088/1757-899X/17/1/012043

Average flank wear P0.3 mm.

Maximum flank wear P0.4 mm.
Nose wear P0.5 mm.
Notching at the depth of cut line P0.6 mm.
Excessive chipping (flaking) or catastrophic fracture of the cutting edge.

Ceramic tool tips used to machine the nickel based Hastelloy-276 workpiece material were examined
by The SEM images of the worn cutting edges. It is seen from these images that wear predominantly
occurred in two regions during the tests: at the depth of cut line and the nose. However, wear at the
nose radius of cutting edge directly influences the machined surface finish since the nose edge is in
direct contact with the newly machined surface. However, further increasing in the depth of cut
increases the extent of tool wear.
In this study, flank wear and excessive chipping wear, which are important problems reducing
tool life, are mainly observed in the machining experiments ceramic tools. It is considered that the tools
having negative and larger approach angle with bigger nose radius must be used in order to solve
chipping wear problem.
4. Conclusion
Turning tests were performed on Nickel based Hastelloy C-276 using two different inserts of ceramic
cutting tools. The influences of cutting speed, tool inserts type and workpiece material were
investigated on the machined surface roughness. Based on the results obtained, the following
conclusions can be drawn:
1.
2.
3.
4.
5.
6.

Cutting speed was found to have a significant effect on the machined surface roughness values.
Influence of Depth of cut was found to affect the surface roughness when it increased from
medium to high value.
Interaction of cutting speed and depth of cut influence the surface roughness and tool wear and
generating BUE in the low to medium speed.
Nose radius wear, evidenced by the SEM examinations, were found to be responsible for the
surface roughness values.
Round insert found to produce better surface roughness associated with decreasing the depth of
cut and increasing the cutting speed.
Feed rate uneducated the surface finish for that it recommended to increase the feed rate with
cutting speed and low to medium depth of cut.

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IOP Publishing
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