📋 Case Study

Energy Sector Inconel 718 Turbine Disk Grooving

Galling and built-up edge leading to catastrophic tool failure during deep grooving

🏗️ Project Overview

Repair and reconditioning of gas turbine disks

🎯 Challenge

Galling and built-up edge leading to catastrophic tool failure during deep grooving

🔧 Design Approach

Hybrid toolpath: ramp-in with adaptive feed, followed by constant engagement with variable pitch end mill and AlCrN coating

📐 Design Diagram

AI-generated project design illustration

📐 Key Calculations

Built-up edge onset temperature

T_BUE ≈ 0.5 × T_melt

Result: 680°C

Target interface temp kept <620°C

Adaptive feed multiplier

f_adapt = f_base × (1 − e^(−ap/d))

Result: 1.42

Compensates for decreasing chip thickness in ramp

📊 Results

Groove consistency improved by 94%; tool change frequency dropped from every 3 parts to every 11; repair lead time cut by 38%

💡 Lessons Learned

• •Variable pitch tools suppress regenerative chatter in tough alloys
• •Adaptive feed must be synchronized with real-time depth feedback

✅ Key Takeaways

• 1Variable pitch tools suppress regenerative chatter in tough alloys
• 2Adaptive feed must be synchronized with real-time depth feedback