Tool wear progression of SiAlON ceramic end mills in five-axis high-feed rough machining of an Inconel 718 BLISK

Abstract The machining of heat-resistant super alloys such as Inconel 718 is still challenging. Processes are characterized by low productivity and high tool costs compared to the machining of steel or titanium materials. SiAlON ceramics offer potential for productivity increases, but are rarely used in industrial application due to uncertainties regarding the correct machining parameters or applicable tool life criteria. In this study, a complex miniaturized high-pressure compressor blisk component was machined using ceramic end mills for the roughing operation. Based on these experiments, the productivity increase of SiAlON ceramic roughing tools was compared to conventional cemented carbide tools. Additionally, a detailed tool wear analysis was conducted. Thereby, a wear-related tool radius decrease could be observed over the machined volume and a linear approximation could be made. Multiple tools exhibited similar tool wear progression.