An experimental investigation on the effect of radial rake angle and machining conditions during end milling on wear resistance and residual stress of nimonic 263 alloy

The tribological and mechanical protection offered to end milled nimonic 263 alloy by the Severe Plastic Deformation (SPD) through machining has been undertaken in the current work. The dry milling of Nimonic 263 alloy has been carried out with a TiAlN coated tungsten carbide tool using vertical machining center. In this study, the surfaces of end milled nimonic 263 are analyzed through x-ray Diffraction Line Profile Analysis (XRDLPA) to evaluate the possible transformation on residual stress using measured interplanar distance between two parallel atomic planes. The quantifiable contributions of machining conditions such as tool nomenclature and machining parameters on the provoked beneficial residual stress on the top surface of the machined samples are evaluated. The SPD processed samples through machining have exposed a significant increment in residual stress which leads to increase the hardness and wear resistance compared to the nascent sample. Further, it reveals that the tool nomenclature has a great extent on the wear resistance followed by machining parameter. Additionally, this study has been carried out to obtain significant machining parameter and tool nomenclature which reflects higher wear resistance of Nimonic 263. (paper)