OBRABOTKAMETALLOV Vol. 28 No. 2 2026 96 TECHNOLOGY Cutting forces, chip morphology and wear characteristics in milling of Inconel 625 alloy produced by EBAM Artem Babaev a, *, Viktor Kozlov b, Nikolai Savchenko c, Artem Semenov d, Roman Tsygankov e National Research Tomsk State University, 36 Lenin Avenue, Tomsk, 634050, Russian Federation a https://orcid.org/0000-0003-2334-1679, temkams@mail.ru; b https://orcid.org/0000-0001-9351-5713, kozlov-victor@bk.ru; c https://orcid.org/0000-0001-8254-5853, savnick@ispms.ru; d https://orcid.org/0000-0002-8663-4877, artems2102@yandex.ru; e https://orcid.org/0000-0002-2660-2312, tsygankovrs@gmail.com Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2026 vol. 28 no. 2 pp. 72–98 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2026-28.2-72-98 ART I CLE I NFO Article history: Received: 24 March 2026 Revised: 11 April 2026 Accepted: 14 April 2026 Available online: 15 June 2026 Keywords: Inconel 625 Milling Additive technologies Cutting force Chip Wear Funding The work was supported by the Russian Science Foundation (project No. 23-79-10166, https://rscf.ru/en/ project/23-79-10166/). ABSTRACT Introduction. Nickel-based alloys such as Inconel 625 are widely used in the aerospace industry due to their high heat resistance and corrosion resistance. However, their machining is complicated by the low thermal conductivity of the material, its tendency to work hardening, and accelerated tool wear. The advent of additive technologies makes it possible to obtain blanks close to the fi nal shape, but the machinability of such materials has not been suffi ciently studied, especially taking into account the anisotropy of properties caused by synthesis conditions. In this regard, the study of cutting forces, the explanation of chip morphology, and the description of the causes of tool wear during milling of additively manufactured Inconel 625 is an urgent task. Methods. The samples were obtained by electron beam additive manufacturing (EBAM) from Inconel 625 wire. Milling was carried out with uncoated cemented carbide end mills. The cutting forces were recorded using a three-component dynamometer Kistler mod. 9257BA. The microstructure, chip morphology, and tool wear were studied by scanning electron microscopy using energy-dispersive analysis and X-ray diff raction analysis. Results and discussion. It has been found that in conventional milling, the cutting forces increase linearly with increasing feed rate. The cutting speed of 23.8 m/min reduces cutting forces compared to 11.9 m/min, but leads to an increase in chip length and deterioration of its removal. Machinability anisotropy is revealed: the cutting forces along the synthesis direction exceed the corresponding values when milling transversely across, which correlates with a higher yield strength in the longitudinal direction. The chip length increases with increasing feed rate and cutting speed, reaching 1.55 mm under maximum conditions, while the chips lose their coiled shape and become cracked. The dominant wear mechanism is adhesion-fatigue wear, confi rmed by the presence of WC particles on the rake surface of the chips and the formation of Cr23C6 and NiW phases on the cutting edges. Oxidative wear does not play a signifi cant role. X-ray diff raction analysis showed a decrease in the initial crystallographic texture in the chips and on the machined surface, as well as a broadening of the peaks, indicating severe plastic deformation. Conclusions. Rational milling parameters have been determined (cutting speed from 11.9 to 23.8 m/min, feed rate of no more than 200 mm/min, depth of cut up to 1 mm, width of cut up to 7 mm), ensuring tool operability. An increase in the feed rate to 250 mm/min leads to catastrophic failure of the cutting edges. The results obtained can be used to develop technological recommendations for the subtractive machining of parts made of additively manufactured Inconel 625 (EBAM). For citation: Babaev A.S., Kozlov V.N., Savchenko N.L., Semenov A.R., Tsygankov R.S. Cutting forces, chip morphology and wear characteristics in milling of Inconel 625 alloy produced by EBAM. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2026, vol. 28, no. 2, pp. 72–98. DOI: 10.17212/1994-6309-2026-28.2-72-98. (In Russian). ______ * Corresponding author Babaev Artem S., Ph.D. (Engineering), Senior Researcher National Research Tomsk State University, 36 Lenin Avenue, 634050, Tomsk, Russian Federation Tel.: +7 952 805-09-26, e-mail: temkams@mail.ru References 1. M’Saoubi R., Outeiro J.C., Chandrasekaran H., Dillon O.W. Jr., Jawahir I.S. A review of surface integrity in machining and its impact on functional performance and life of machined products. International Journal of Sustainable Manufacturing, 2008, vol. 1 (1–2). pp. 203–236. DOI: 10.1504/IJSM.2008.019234.
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