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<p>The present study reports evaluation of the milling behaviour of Inconel 718 manufactured through Laser Direct Energy Deposition-based additive manufacturing and to achieve optimum set of cutting parameters in machining the alloy. The investigation focuses on understanding the role of key cutting parameters that influence surface roughness, chip morphology, and tool wear and to identify suitable machining conditions for additively manufactured IN718. Milling experiments were carried out using L9 factorial design with systematic variation of cutting speed (80, 100, and 120&#xa0;m/min), feed rate (0.08, 0.10, and 0.12&#xa0;mm/rev), and depth of cut (0.2, 0.4, and 0.6&#xa0;mm). The results demonstrate clear differences in machinability when compared with conventional Inconel 718 alloy. The surface roughness (Ra) of additively manufactured alloy varies between 0.383 and 1.001&#xa0;µm, whereas the exhibited values are between 0.533 and 0.996&#xa0;µm for conventional material. Similarly, tool wear observations indicate aggressive wear behaviour in AM alloy with a maximum flank wear (Vb) of 1.163&#xa0;mm compared to 0.371&#xa0;mm in normal IN718 for identical machining conditions. These findings confirm the inherent microstructural differences in AM 718 and conventional alloy that influence the machining responses. A systematic and careful optimization of machining parameters is essential, not only to achieve acceptable surface quality but also to mitigate excessive tool wear and reduce the risk of premature or catastrophic tool failure associated with the anisotropic microstructure of AM IN718.</p>

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Milling Performance of Additively Manufactured Inconel 718: Cutting Parameters Effect on Tool Wear, Surface Quality, Chip Morphology, and Microstructure

  • 期刊论文

  • 发表日期：

    2026年7月28日

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  • Shreyas R. Itankar,
  • Mahesh Kumawat,
  • Samarth Jain,
  • Veena Aware,
  • T. V. K. Gupta

摘要

The present study reports evaluation of the milling behaviour of Inconel 718 manufactured through Laser Direct Energy Deposition-based additive manufacturing and to achieve optimum set of cutting parameters in machining the alloy. The investigation focuses on understanding the role of key cutting parameters that influence surface roughness, chip morphology, and tool wear and to identify suitable machining conditions for additively manufactured IN718. Milling experiments were carried out using L9 factorial design with systematic variation of cutting speed (80, 100, and 120 m/min), feed rate (0.08, 0.10, and 0.12 mm/rev), and depth of cut (0.2, 0.4, and 0.6 mm). The results demonstrate clear differences in machinability when compared with conventional Inconel 718 alloy. The surface roughness (Ra) of additively manufactured alloy varies between 0.383 and 1.001 µm, whereas the exhibited values are between 0.533 and 0.996 µm for conventional material. Similarly, tool wear observations indicate aggressive wear behaviour in AM alloy with a maximum flank wear (Vb) of 1.163 mm compared to 0.371 mm in normal IN718 for identical machining conditions. These findings confirm the inherent microstructural differences in AM 718 and conventional alloy that influence the machining responses. A systematic and careful optimization of machining parameters is essential, not only to achieve acceptable surface quality but also to mitigate excessive tool wear and reduce the risk of premature or catastrophic tool failure associated with the anisotropic microstructure of AM IN718.