Influence of Dispersed Phase Reinforcement on Performance and Wear Mechanism of Ceramic Tools in Rough Milling of Inconel 718

Machining nickel-based superalloys, such as Inconel 718, poses a significant technological challenge due to their high-temperature strength and low thermal conductivity, leading to rapid tool wear. This paper presents a comprehensive comparative analysis of two roughing strategies: high-feed milling and plunge milling, utilizing a unique custom-designed milling head. The primary objective was to evaluate the impact of tool material reinforcement on the process by comparing SiC whisker-reinforced ceramic inserts (CW100) with non-reinforced inserts (CS300). The experiment involved measuring cutting force components, power consumption, and analyzing tool wear progression (VBB) and mechanisms. Results showed that the presence of the reinforcing phase is critical for reducing the axial force component (Fz), particularly in plunge milling, where CW100 inserts achieved a 30–35% force reduction and avoided the catastrophic failure observed in non-reinforced ceramics. Microscopic analysis confirmed that composite inserts undergo predictable abrasive wear, whereas CS300 inserts are prone to brittle fracture and spalling. Multi-criteria optimization using Grey Relational Analysis (GRA) identified high-feed milling with reinforced inserts as the most efficient strategy, while also positioning plunge milling with composites as a competitive, less energy-intensive alternative.