Jam.

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Materials
Technology
ELSEVIER Journal of Materials Processing Technology 55 (1995) 63-69

Surface abuse when machining cast iron (G-17) and nickel-base

superalloy (Inconel 718) with ceramic tools
E.O. Ezugwu*, S.H. Tang
South Bank University, London, SE10AA, UK

Industrial summary

Single-point continuous-turning tests were carried out on a G-17 cast iron and a nickel base, Inconel 718, alloy using round and
rhomboid-shaped pure oxide (AI20 3 + ZrO2) and mixed oxide (A1203 + TiC) ceramic tools to study the extent of damage on the
machined surfaces under optimum cutting conditions. The test results show that improved surface finish and lesser damage were
obtained when machining the work materials with round inserts of both tools tested. Machining with the mixed-oxide ceramic tools
generally produced better surface finish than with the pure oxide ceramics because of their improved hot hardness, fracture toughness
and wear resistance. Hardness values of the outer layer of the machine surfaces (up to 0.20 mm deep) show that the cutting conditions
chosen produced significant variation and values well above the average hardness of the work materials because of the high rate of
work hardening, increased compressive stresses and plastic deformation, particularly for the nickel base, Inconel 718, alloy.
The hardness value of the surface layer was also increased by prolonged machining. MetaUographic examination of the machined
surfaces revealed minimum surface alteration after machining grey cast iron, unlike the very severe damage (tearing and microstruc-
tural changes) observed after machining the nickel alloy. Surface damage on the nickel alloy only became severe after machining with
the round inserts for three minutes, unlike the rhomboid-shaped inserts which produced poor surfaces even at the start of machining.

1. Introduction are produced by the impression of the tool nose radius on

Control of surface finish is required to give the most
suitable condition for long life, fatigue resistance, max-
imum efficiency and functional interchangeability of
a machined component at minimum cost. The surface
finish generated on a workpiece in a machining operation
has been considered as the sum of two independent
effects: the "ideal" surface roughness and the natural
surface roughness [1]. The ideal surface roughness is
a result of the geometry of the tool and the feed, whereas
the natural surface roughness is caused by the irregulari-
ties in the machining operation. The ideal surface rough-
ness is the best surface finish that can be obtained with
a given tool-shape and feed-rate and can only be
achieved if the effect of natural surface roughness is
eliminated. The type of chip produced during the ma-
chining operation has a significant effect on the surface
finish produced. Poor surfaces are generally associated
with one or more of the following: chatter, feed marks,
microchips and sponzipfel. Chatter is caused by the peri-
odic vibration of the tool and/or workpiece. Feed marks
*Corresponding author.
each revolution of the workpiece. A microchip forms at
the flank face of a tool, this being the counterpart of the
built-up edge which normally forms on the rake face of
a tool. Microchips occur through a process of shear with
the development of a primary deformation zone similar
to that normally associated with chip production at the
tool rake face. The size of the microchips are dependent
on the stability of the system. Sponzipfel is enhanced by
the formation of a series of notches (or grooves) on the
cutting edge of a worn tool.
Surface abuse refers to the extent of damage on the
surface of a machined component during machining as
a result of the interaction of process energies (eg mechan-
ical, electrochemical, thermo-chemical, etc.) and material
properties (eg tensile, ductility, hardness, etc.) in a consis-
tent manner. Mechanical energy is used to remove metal
in the traditional machining processes by a shearing
action between the tool and the workpiece. This action
results in heat generation and plastic deformation. The
heat generated usually alters the microstructure of the
alloy and induce residual stress. Residual stress will also
be induced by plastic deformation without heat [2]. Heat
and deformation, singly or in combination, may produce
cracks and microstructural changes during machining.

0924-0136/95/$09.50 © 1995 Elsevier Science S.A. All rights reserved

SSDI 0 9 2 4 - 0 1 3 6 ( 9 5 ) 0 1 7 8 6 - E
64 E.O. Ezugwu, S.H. Tang /Journal of Materials Processing Technology 55 (1995) 63 69

A reduction in the heat generated during machining can Table 1

be achieved by the use of sharp tools and proper selection Properties of the ceramic cutting tool materials
of machining parameters. Alloys which possess high yield
Pure oxide Mixed oxide
strength at elevated temperatures (e.g. superalloys) will
develop a high residual stress. Both tensile and compres- Nominal composition (vol. %) A1203 f> 99 AI20 3 = 70
sive residual stresses can be produced during machining ZrO2 ~< 1 TiC = 30
operations. Excessive surface heat produces a tensile pat- Density (g/cm 3) 3.99 4.29
tern, whilst a compressive pattern stems from the over- Hardness: HV lkgf (kg/mm 2) 1800 2230
Hot hardness (1000°C) 800 900
riding of the heat effect by the tensile plastic deformation HV 18 kgf load (kg/mm 2)
of the tool on the workpiece [2]. Surface alteration com- Toughness, Klc ( M P a m 1/2) 4.3 4.5
mon to non-traditional machining processes are high Young's modulus (GPa) 390 416
surface roughness, inter-granular attack and re-cast Thermal conducitivity (Cals/cm sk)
layer. Inter-granular attack is a form of corrosion in Room temperature 0.0708 0.0517
1000°C 0.0181 0.0236
which reactions are concentrated at the surface grain Bend strength (MPa) 700 910
boundaries, usually in the form of sharp notches. Re-cast Thermal-expansion coefficient
layer refers to surfaces that have, at some point in the 10-6/°C) R o o m temperature
processing, become molten and then re-solidfied. - 1000°C 8.2 8.6
This paper examines the surface abuse in terms of
surface texture and surface integrity after machining cast
iron (G-17 grade) and nickel base superalloy (Inconel inserts were clamped mechanically on rigid kenloc
718) with pure oxide (A1203 + ZrO2) and mixed oxide MCLNR and MRGNR tool-holders to provide the
(A1203 + TiC) ceramic tools at various cutting condi- following geometry during machining.
tions. Detailed tool-life studies of the cutting tools were
not carried out: rather the effect of various cutting condi- M C L N R ( r h o m b o i d ) M R O N R (round)
tions as well as tool geometry/shape on surface texture Approach angle 95 ° 90 °
and surface integrity after the machining of the work Side rake angle - 5° - 5°
materials were investigated. Back rake angle 5° - 5°
All clearance angle 6° 5°

Machining was halted after each minute in order to

2. Experimental procedures
The machining trials were carried out by single-point
continuous turning of previously cleaned, centred and
trued workpiece bars (465 mm long and 240 mm dia-
meter) using a computer-numerically-controlledmachine
tool (Torshalla $250). This lathe machine is equipped
with variable spindle speed from 40 to 2800 rpm,
variable feed from 0.05 to 2.8 mm/rev and a 38 kW
motor drive, thus enabling any particular surface
speed on a suitable bar diameter to be achieved.
Coolant was not used for the turning tests because of
the low thermal shock properties of ceramic tools. The
materials used conform to the following specifications
(percentage):
record the wear on the insert as well as the surface finish
generated on the workpiece. Tool wear was measured
with the aid of a travelling microscope connected to
a digital read-out device, whilst the surface-roughness
values were recorded using a portable stylus-type instru-
ment. Further machining was stopped and an insert
rejected when any of the following wear criteria was
reached.
(1) Average flank wear /> 0.40 mm
(2) Maximum flank wear >1 0.70 mm
(3) Crater wear 1> 0.14 mm
(4) Notching (at the depth of cut or tool nose)
/> 1.00 mm
(5) The surface finish on the work material exceeds 5 ~tm
(CLA)

Material C Si P Mn Mo S Fe Ni Cr Nb
G-17 Cast Iron 3-3.5 2-2.5 0.3-0.7 0.8 -- 0.5 Bal 1-1.5 0.35 --
Inconel 718 .08 0.35 -- 0.35 3.05 0.015 18.5 Bal 19.0 5

The Inconel 718 workpiece underwent subsequent
heat treatment after casting in order to achieve the
required properties. The tools used were 80 ° rhomboid
and round inserts corresponding to ISO designation
CNGN 12 04 12T and RNGN 12 07 00, respectively, with
a 0.20 mm x 12° chamfer. The physical properties of the
ceramic tool materials are illustrated in Table 1. The
(6) Fracture or catastrophic failure occurs.
Samples of the machined surface at the start of cutting
and after machining for three minutes were taken from
the bar for examination of the surface alteration using
optical microscopy. The hardness values of these samples
were recorded using a micro-hardness tester (officine
Galileo Microscan OM) with a Vickers indenter.
 E.O. Ezugwu, S.H. Tang / Journal of Materials Processing Technology 55 (1995) 63-69 65

3. Experimental results and discussion Table 2

Data recorded at various intervals when cutting G-17 cast iron
The machining trials were carried out under the fol-
Tool grade Cutting Flank wear (ram) Surface
lowing cutting conditions: time roughness
(rain) AFW MFW (lam)
G-17 cast iron Inconel 718
Pure oxide 1 0.012 0.023 4.11
Cutting speed (m/min)
(CNGN 12 04 12T) 2 0.020 0.045 4.23
Pure oxide ceramics 300 152
3 0.028 0.060 4,50
Mixed oxide ceramics 500 152
Pure oxide 1 0.012 0.023 1,99
Feed rate (mm/rev) 0.25 0.125
(RNGN 12 07 00) 2 0.020 0.045 2,17
Depth of cut (ram) 2.0 2.0
3 0.030 0.062 4.50
These machining parameters were based on the optimum Mixed oxide 1 0.023 0.035 2.96
conditions established in previous work [3,4]. The G-17 (CNGN 12 04 12T) 2 0.035 0.056 3.45
cast iron is an intermediate grade of grey cast iron that is 3 0.038 0.059 3.71
Mixed oxide 1 0.019 0.051 3.54
used widely in the manufacturing (especially automobile) (RNGN 12 07 00) 2 0.023 0.055 3.79
industry. It contains graphite in flake form which is 3 0.030 0.057 4.52
distributed evenly in a largely ferrite matrix. Nickel-
based alloys are mainly used in the aerospace industry AFW = Average flank wear
and are usually referred to as superalloys because of their MFW = Maximum flank wear

high-temperature properties. Inconel 718 is a nickel-base

precipitation-strengthening alloy. The main structure of
the alloy is the face centre cubic (fcc) austenitic solid-
solutions matrix known as gamma (7) phase with a pre-
cipitated nickel aluminium titanium [Ni3(A1 Ti)] known
6'0'
as gamma prime (y') phase as the main strengthening
KEY
phase. Another strengthening phase present in Inconel 1

o = CNG. 1= o41z r t/ PURE OX,OE

718 is the nickel niobium (Ni3Nb) phase known as ::L S'O RNON ~2 O700 ~ CEaA~cs
CNGN 12 0412T ~ MIXED OxIOE
gamma double prime (7"). These precipitated phases in- u.I [ ; RNGN 120'700 "J CERN~ICS
crease the strength and hardness of the alloy. The out- •i- 4.0

standing characteristics of Nickel alloys, such as their

good strength and creep resistance at elevated temper- w
~ 3-o
u.
atures as well as their austensitic matrix, severely hinder
their machinability [5]. 2-0

1.o ¸
u
4. Machining of G-17 cast iron

Table 2 shows the flank-wear and surface-roughness
values recorded when machining G-17 cast iron with the
rhomboid (CNGN 12 04 12T) and round (RNGN 12 07
00) shapes of the pure oxide and mixed oxide grades of
ceramic tools. A plot of the surface roughness versus
cutting time is shown in Fig. l(a). This shows that the
surface roughness value in each test was lower than the
5 ~tm rejection criterion after cutting for 3 min. Cast iron
is a brittle material containing graphite, which lowers the
shear strength and assists in lubricating the tool-work
interface during machining, resulting in the production of
discontinuous chips. The graphite flakes also weaken the
material at the shear plain and initiate fracture [6-8].
They also reduces temperature and friction at the
tool-chip and tool-workpiece interfaces through bound-
ary lubrication, leading to a significant reduction or the
absence of compressive stress at these interfaces and
therefore an improvement in the surface finish. Fracture
occurred through the graphite zone when machining
110 2'.0 3~0 t'O Z'.0 3'0
(a) CUTTING TiME ( MIN5 ) (b)
Fig. 1. Surface-roughness values at various intervals when machining:
(a) G-17 Cast Iron and (b) Inconel 718.
G-17 cast iron with the ceramic tools, as shown in the two
distinct areas observed on the machined surface (Fig. 2).
The relatively smooth areas show where actual cutting
occurred, whilst the rough, irregular areas show where
fracture has occurred. The fractured area shows where
segments of the work material have been removed from
below the general level of the surface leaving cavities. The
consequence of this type of action is a high surface-
roughness value.
The progressive deterioration of the surface finish with
prolonged machining (Fig. l(a)) can also be caused by the
shape (or geometry) of the cutting tool and the extent of
wear. It has been reported that the relative motion at the
66 E.O. Ezugwu, S.H. Tang /Journal of Materials Processing Technology 55 (1995) 63-69
Fig. 2. Machined surface of G-17 cast iron.
interface between the tool nose region and smooth areas
of the freshly machined surfaces generate frictional and
adhesive forces because of the interaction of contacting
asperites [9]. This action will obviously worsen the sur-
face finish generated.
The round (RNGN 12 07 00) inserts produced a better
surface finish than the rhomboid (CNGN 12 04 12T)
inserts at a speed of 300 m/min when machining with the
pure oxide ceramics as expected due to their greater nose
radius which could minimise the saw-tooth effect on the
machined surface. Machining with the mixed oxide ce-
ramic inserts at a higher speed of 500 m/min produced
a greater flank wear rate. Cutting speed and feed rate are
the most important parameters affecting tool wear in
metal cutting. A constant feed rate and depth of cut of
0.25 mm/rev and 2.00 mm respectively were used for
U.O,
420
380
340
3OO
AVERAOE HARONESS OF m.¢¢ MATF'RIAL (27gHVl
~ 260
o
180
140
100
0.'o4 o.~8 0'.,2 o'.,~ o.~o
(a)
Fig. 3. A plot of the hardness values after machining G-17 east iron with ceramic tools for: (a) lmin; and (b) 3min.
machining the G-17 cast iron. The use of a higher speed
of 500 m/min will therefore generate relatively high tem-
perature and stresses (compressive and tensile) during
machining, thus increasing the flank face wear. An in-
crease in the flank wear leads to an increase in the
tool-chip contact length, which in turn increases the
temperature and the compressive stress/pressure. A zone
of intense shear will therefore be developed on the worn
flank face. These developments might lead to the removal
of tool particles at the tool nose. The tool particles
removed from the tool nose tend to weld themselves on
to the freshly generated work surface, resulting in the
generation of a poor surface finish. It was thought pre-
viously that ceramic tools will not weld or adhere easily
to ferrous work materials as do other tool materials, such
as High-Speed Steel and cemented carbide, since they are
non-metallic. Later studies on ceramic tools have shown
that alumina ceramics can also exhibit a tendency towards
welding between the tool and the work material [10].
The relatively high surface-roughness values recorded
after cutting G-17 cast iron with the pure oxide ceramics
(especially with the rhomboid inserts) at a lower speed of
300 m/min (Table 2) could be due the lower hot hardness
and fracture toughness of this grade of ceramics, as illus-
trated in Table 1. These will provide a weak resistance at
the cutting edge during machining, resulting in the loss
(or chipping) of tool particles. The susceptibility of the
pure oxide ceramic tools to chipping will also tend to
alter the cutting edge geometry, thereby increasing the
tool-workpiece contact area. This will also reduce the
clearance angle and at the same time increase the rubbing
of the tool flank face on the newly generated surfaces.
o ', CNGN 12 0412 T], PURE OXIOE
x - RNGN 120700 J CERAMICS
• - CNGN 120/, 12T], MIXED OXIDE
A = RNGN 120700 J CERAMICS
%,
0:04 o:os o:~2 oi~8 o12o
OISTANCE FROM TOP SURFACE (n~m) (b)
 E.O. Ezugwu, S.H. Tang /Journal of Materials Processing Technology 55 (1995) 63-69 67

Table 3
Data recorded at various intervals when machining Inconel 718

Tool grade Cutting Flank wear (mm) Surface

time roughness
AFW MFW (lam)

Pure oxide 0.336 0.769 7.94

(CNGN 12 04 12T) (Excessive notching after 1 minute
= 2.096 mm)
Pure oxide 1 0.248 0.549 2.45
(RGNG 12 07 00) 2 0.283 0.561 2.60
3 0.290 0.671 3.05
Mixed oxide 1 0.203 0.511 6.02
(CNGN 12 04 12T) (Excessive notching after 1 minute
= 4.125 mm)
Mixed oxide 1 0.157 0.404 1.13
Fig. 4. Minimum surface damage observed after cutting cast iron (RNGN 12 07 00) 2 0.239 0.563 1.20
( x 500). 3 0.229 0.472 2.11

Fig. 3 shows variation in the hardness of the surface layer
of G-17 cast iron at various intervals during the machining
operation. The hardness values were significantly greater
than the average hardness of the base material (279HV).
This is caused by the work hardening of the surface layer as
a result of the combination of high compressive stresses and
pressure at the cutting edge during machining. The rate of
work hardening decreases from the top surface towards the
base material, coinciding with the perceived reduction in
stresses (Fig 3). A polished specimen of the machined
surface revealed minimum surface alteration (Fig 4), due
perhaps to the presence of graphite flakes in the G-17
cast iron which facilitate the breaking of the pearlite
matrix to prevent significant tearing of the surface.
AFW = Average flank wear; MFW = Maximum flank wear
5. Machining of Inconel 718
The nickel base, Inconel 718, alloy was machined at
a reduced speed of 152 m/min, a feed rate of
0.125 mm/rev and at a constant depth of cut of 2.00 ram.
Long continuous chips were produced when cutting this
material due to its ductile nature. All the rhomboid-
shaped ceramic tools failed after machining for 1 rain
under these conditions due to excessive notching at the
depth of cut region (see Table 3). The notching was
mainly caused by the strain hardening of the workpiece

KEY
o = CNGNI2D412T!, PURE OXIDE
I = RNGN 1Z D7 O0 J CERAMICS
700
• • CNGN 120~ lZT~, M~XEOOXIDE
• RNGN 1207 O0 J CERAMICS
65D

60D

550

500

45D
A V E R A G ~ S E MATERIAL(AZSHV)
400

350

3DD
0"04 0"OS 0:12 0"16 0;20 0~04 0"0S 0'12 0104 o'r0e 01T2
DISTANCE FROMTOP SURFACE(ram)

(a) (b) (c)

Fig. 5. A plot of the hardness values after machining Inconel 718 with ceramic tools: (a) start of cutting; (b) after lmin; and (c) after 3min,
68 E.O. Ezugwu, S.H. Tang / Journal of Materials Processing Technology 55 (1995) 63-69

Fig. 6. Tearing observed on the surface layer after cutting Inconel

718( x 500).
Fig. 7. Severenotchingobservedon a ceramictool usedto cut Inconel
718.
during machining as a result of the high pressure~com-
pressive stresses at the tool-workpiece interface. The
cant tearing on the surface of a machined component is
hardness of the surface layer of the workpiece increased
undesirable since it reduces the fatigue strength, which is
with prolonged machining and was well above the aver-
an important factor in the design of high strength and
age hardness of the base material (425 Hv) due to the
reliable components.
relatively high rate of work hardening as well as the
plastic deformation of Inconel 718 (Fig. 5). Evidence of
plastic deformation on the surface layer after machining
6. C o n c l u s i o n s
Inconel 718 is shown in Fig. 6 by the elongation of the
grain structures and the directional orientation of the
1. The shape and geometry of cutting tools, play an
grain boundaries. It has been reported that alloys that
important role in determining the nature of machined
are strengthened by heat treatment (e.g. nickel and tita-
surfaces. The round inserts produced a better surface
nium alloys) are the most sensitive to microstructural
finish than the rhomboid inserts when machining G-17
change [2]. The continuous rubbing of the work
cast iron and Inconel 718 under the cutting conditions
hardened chip/surface layer and the cutting tool could
tested.
result in the removal of tool particles by abrasion and/or
2. Prolonged machining with the two grades of ceramic
attrition wear mechanisms, leading to severe notching
tools resulted in an increase in the hardness of the
(Fig. 7) : the mechanism of notch formation has been
surface layer to well above the average hardness values
described elsewhere I-5, 11]. The severe notching as well
of the work materials. This increase is more pro-
as the high flank wear led to the deterioration of the
nounced with Inconel 718 due to its high rate of work
surface finish when cutting with the rhomboid-shaped
hardening, increased compressive stresses and plastic
ceramic inserts (Table 3). Fig. 1 (b) shows that the
deformation.
surface finish worsened with prolonged machining when
3. There was virtually no surface alteration after
cutting with the round ceramic inserts. The relationship
machining the G-17 cast iron with ceramic tools under
between the rate of flank wear and surface roughness
the specified cutting conditions. Significant tearing
can also be seen in Table 3. A rougher surface finish
and considerable microstructural changes occurred on
was produced where there was high flank wear due to
the machined surfaces of the nickel base, Inconel 718,
increased tool-workpiece contact area and the sub-
alloy.
sequent reduction of the clearance angle thus increasing
the rubbing of the flank face on the newly generated
surface. The relatively low fracture toughness and hot References
hardness of the pure oxide ceramic tools (Table 1) ex-
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roughness values. (1986).
Tearing of the surface layer of the Inconel 718 alloy [2] R.M.Niemi,Integrity prediction, SMETechnicalPaper, Dearbon
- Michigan,(1971).
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6), this being caused mainly by the relatively high tough- mance of ceramic tool materialsfor The Machining of cast, iron,
ness and strength of Inconel 718. The presence of signifi- Wear, 135 (1989) 147-159.
 E.O. Ezugwu, S.H. Tang / Journal of Materials Processing Technology 55 (1995) 63-69
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1'61 E.M. Trent, Metal Cutting, Butterworth, London (1977).
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69
[8] G.F. Ruff and B.K. Doshi, Relationship between mechanical prop-
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