However, when machining expensive parts made of superalloys or titanium alloys, the cost of the tool is only a small fraction of the overall value of the part. Therefore, tool utilization (also known as tool utilization index) is a more relevant measure. When comparing two example tools, if one tool is held for 10 minutes and a workpiece is produced, the tool cost is one tool per workpiece. Another tool, used in different ways, may only last for 5 minutes, but produces two parts. Even though the life of the second tool is half the life of the first tool in terms of minutes, the part production is doubled. The goal is to produce the maximum number of qualified parts in the shortest amount of time at an acceptable price. Considering the high cost of high-temperature alloy parts, the tool utilization index is a better measure of real productivity.
Stainless steel, patented in various forms about 100 years ago, became the first step towards modern superalloys. In the first stainless steel alloy, chromium is added to the steel for oxidation and corrosion resistance – in basic stainless steel alloys, the chromium content is at least 10.5% of the total weight. Next, in order to improve the hardness and rigidity of the stainless steel, nickel was added. As alloys are used in increasingly harsh environments, the proportion of nickel increases, and eventually nickel becomes the main alloying element in the material. In today's well-known superalloy 718 (trade name Inconel 718), the nickel content is 50% to 55%, the chromium content is 17% to 21%, the other elements are 10%, and the remainder is iron. Modern high temperature alloys and titanium based alloys have excellent strength, heat resistance, corrosion resistance and stability.
In the face of these difficult-to-machine new workpiece materials, manufacturers should first try to use familiar processing practices. However, only when they use the tools and techniques that are specifically designed for these specific materials and processes can they achieve maximum productivity.
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