Milling of Nickel-based Superalloy by Trochoidal Strategies

In this scientific study, the authors have dealt with slot milling of nickel-based superalloy. These alloys are among the most difficult materials to machine, and are widely used in aerospace and energy industries. Slot milling is a particular problem because tool wear happens quickly and tool breakages are common. This is why reconditioned tools are often used in an industrial setting, which can significantly reduce tool-related costs. The machining strategy employed also has a major impact on the lifecycle of the tool and the quality of the machined surface, so choosing the right strategy is an important factor. Therefore, the authors have chosen two traditional trochoidal strategies, the circular and swinging tool path and a modern tool path, the Autodesk Inventor HSM adaptive strategy. The effects of the tool geometry of the new and the renovated tools and the trochoidal toolpaths were tested focusing on the cutting forces, torques and the average surface roughness on the bottom of the milled slots. The aim was to determine the best strategy for these parameters and investigate the effects of the new and the restored tool geometry.