Milling of Inconel 625 blanks fabricated by wire arc additive manufacturing (WAAM)

Introduction. Additive manufacturing technologies, in particular wire arc additive manufacturing (WAAM), have been gaining increasing popularity recently. This method allows for the production of blanks with significantly increased hardness compared to traditional methods such as forging, which in turn significantly increases the cutting force during subsequent machining. The present study is aimed at investigating the cutting forces during milling of samples made from the high-strength, heat-resistant alloy Inconel 625 obtained by WAAM. The aim of the work is to investigate the influence of microstructure and properties of Inconel 625 fabricated by WAAM, on cutting forces during milling. Particular attention is paid to the search for optimal cutting modes, providing minimization of cutting forces and vibrations in the “machine-utility-tool-part” system. Methods of research. Samples were produced by WAAM using wire made from heat-resistant nickel-based alloy Inconel 625. A comprehensive analysis of the microstructure of the obtained samples was carried out using modern materials science methods. The main attention is paid to the experimental study of cutting forces during milling using different machining modes (cutting speed, feed rate, and depth of cut) and types of cutters. Results and Discussion. The microstructure of Inconel 625 samples obtained by WAAM is characterized in detail. Optimal milling modes will be determined to ensure efficient machining of the material, taking into account its high hardness and strength. It is expected that machining of Inconel 625 blanks will require high-strength carbide milling cutters, possibly of special geometry and with increased wear resistance, with a larger diameter compared to milling of steel 0.4 C-13 Cr. The results of the study allow developing recommendations for selecting optimal cutting modes minimizing cutting force, cutting edge temperature, tool wear and vibrations in the “machine-utility-tool-part” system, thereby improving processing productivity and accuracy.