An optimization technique on ultrasonic and cutting parameters for drilling and deep drilling of nickel-based high-strength Inconel 738LC superalloy with deeper and higher hole quality

2015 ◽  
Vol 82 (5-8) ◽  
pp. 877-888 ◽  
Author(s):  
V. Baghlani ◽  
P. Mehbudi ◽  
J. Akbari ◽  
Erfan Zal Nezhad ◽  
Ahmed A. D. Sarhan ◽  
...  
Keyword(s):  
Optimization Technique ◽  
High Strength ◽  
Cutting Parameters ◽  
Deep Drilling ◽  
Hole Quality ◽  
Inconel 738Lc

Genetic Algorithm-Based Optimization of the Thin-Walled Tube of High Strength Aluminum Alloy in Diamond Turning Process

2011 ◽  
Vol 175 ◽  
pp. 347-351
Author(s):  
Bao Xing Zhang ◽  
Bin Lin ◽  
Zhi Lin Han ◽  
Lei Zhang
Keyword(s):  
Genetic Algorithm ◽  
Aluminum Alloy ◽  
Optimization Technique ◽  
High Strength ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Turning Process ◽  
High Strength Aluminum Alloy ◽  
Thin Walled Tube ◽  
Thin Walled

Optimization of the cutting parameters is one of the most important contents in diamond turning process of the thin-walled tube of high strength aluminum alloy. Cutting conditions have an influence on reducing the production time and deciding the quality of the final workpiece. This paper proposes an optimization technique based on genetic algorithms (GA) for the determination of the cutting parameters. As the experimental results show, it is very efficient that the proposed genetic algorithm-based procedure for solving this problem.

scholarly journals Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1783
Author(s):  
Hamza A. Al-Tameemi ◽  
Thamir Al-Dulaimi ◽  
Michael Oluwatobiloba Awe ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Good Practice ◽  
Cutting Tools ◽  
Statistical Design ◽  
Cutting Parameters ◽  
Statistical Design Of Experiments ◽  
Hole Quality ◽  
Coated Tools ◽  
Tool Coating

Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.

scholarly journals Prediction of Tool Lifetime and Surface Roughness for Nickel-Based Waspaloy

2020 ◽  
Vol 2020 ◽  
pp. 1-12
Author(s):  
Shao-Hsien Chen ◽  
Chung-An Yu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Predictive Values ◽  
Actual Surface ◽  
Wide Range

In recent years, most of nickel-based materials have been used in aircraft engines. Nickel-based materials applied in the aerospace industry are used in a wide range of applications because of their strength and rigidity at high temperature. However, the high temperatures and high strength caused by the nickel-based materials during cutting also reduce the tool lifetime. This research aims to investigate the tool wear and the surface roughness of Waspaloy during cutting with various cutting speeds, feed per tooth, cutting depth, and other cutting parameters. Then, it derives the formula for the tool lifetime based on the experimental results and explores the impacts of these cutting parameters on the cutting of Waspaloy. Since the impacts of cutting speed on the cutting of Waspaloy are most significant in accordance with the experimental results, the high-speed cutting is not recommended. In addition, the actual surface roughness of Waspaloy is worse than the theoretical surface roughness in case of more tool wear. Finally, a set of mathematical models can be established based on these results, in order to predict the surface roughness of Waspaloy cut with a worn tool. The errors between the predictive values and the actual values are 5.122%∼8.646%. If the surface roughness is within the tolerance, the model can be used to predict the residual tool lifetime before the tool is damaged completely. The errors between the predictive values and the actual values are 8.014%∼20.479%.

Designing and implementation of a novel online adaptive control with optimization technique in hard turning

2020 ◽  
pp. 095965182095219
Author(s):  
Vahid Pourmostaghimi ◽  
Mohammad Zadshakoyan
Keyword(s):  
Adaptive Control ◽  
Tool Wear ◽  
Hard Turning ◽  
Cutting Tool ◽  
Optimization Technique ◽  
Cutting Parameters ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Parameters ◽  
Optimization Methodology

Determination of optimum cutting parameters is one of the most essential tasks in process planning of metal parts. However, to achieve the optimal machining performance, the cutting parameters have to be regulated in real time. Therefore, utilizing an intelligent-based control system, which can adjust the machining parameters in accordance with optimal criteria, is inevitable. This article presents an intelligent adaptive control with optimization methodology to optimize material removal rate and machining cost subjected to surface quality constraint in finish turning of hardened AISI D2 considering the real condition of the cutting tool. Wavelet packet transform of cutting tool vibration signals is applied to estimate tool wear. Artificial intelligence techniques (artificial neural networks, genetic programming and particle swarm optimization) are used for modeling of surface roughness and tool wear and optimization of machining process during hard turning. Confirmatory experiments indicated that the efficiency of the proposed adaptive control with optimization methodology is 25.6% higher compared to the traditional computer numerical control turning systems.

scholarly journals Intelligent Selection of Machining Parameters in Multipass Turnings Using Firefly Algorithm

2014 ◽  
Vol 2014 ◽  
pp. 1-6 ◽  
Author(s):  
Abderrahim Belloufi ◽  
Mekki Assas ◽  
Imane Rezgui
Keyword(s):  
Production Cost ◽  
Firefly Algorithm ◽  
Optimization Technique ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Metal Parts ◽  
Multipass Turning ◽  
Optimal Cutting Parameters ◽  
Selection Of

Determination of optimal cutting parameters is one of the most important elements in any process planning of metal parts. In this paper, a new optimization technique, firefly algorithm, is used for determining the machining parameters in a multipass turning operation model. The objective considered is minimization of production cost under a set of machining constraints. The optimization is carried out using firefly algorithm. An application example is presented and solved to illustrate the effectiveness of the presented algorithm.

Multi-Objective Optimization on Drilling of Titanium Alloy (Ti6Al4V)

2013 ◽  
Vol 763 ◽  
pp. 29-49 ◽  
Author(s):  
A. Prabukarthi ◽  
V. Krishnaraj ◽  
M. Senthil Kumar
Keyword(s):  
Titanium Alloy ◽  
Thrust Force ◽  
Optimization Technique ◽  
Weight Ratio ◽  
High Strength ◽  
Hole Diameter ◽  
Machining Process ◽  
Multi Objective ◽  
Titanium Alloy Ti6al4v ◽  
Exit Burr

Titanium alloys present superior properties like resistance to corrosion, high strength to weight ratio etc, but possess poor machinability. Titanium alloy Ti-6Al-4V is the most commonly used titanium alloy in aerospace and medical device industries. Titanium and its alloys are notorious for their poor thermal properties and are classified as difficult-to-machine materials. Drilling is an important machining process since it is involved in nearly all titanium applications. It is desirable to develop optimized drilling processes for Ti and improve the hole characteristics such as hole diameter, circularity and exit burr of currently available processes. Due to the low machinability of the alloys under study, selecting the machining conditions and parameters is crucial. The range of spindle speed and feed rate, which provide a satisfactory tool life, is very limited. The hole quality (hole diameter and circularity), thrust force, torque and exit burr were evaluated at various spindle speeds, feed rates combinations. The optimized parameter is chosen using the multi-objective weighted sum optimization technique.

scholarly journals Milling of Complex Surfaces of EN 10060 Steel after HVOF Sprayed NiCrBSi Coatings

Coatings ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 744 ◽  
Author(s):  
Jan Valíček ◽  
Marta Harničárová ◽  
Jan Řehoř ◽  
Milena Kušnerová ◽  
Jaroslava Fulemová ◽  
...  
Keyword(s):  
Steel Substrate ◽  
Spherical Surface ◽  
High Strength ◽  
Cutting Parameters ◽  
Surface Adhesion ◽  
Complex Surfaces ◽  
Optimal Cutting Parameters ◽  
Spraying Process ◽  
Nicrbsi Coatings

The high-velocity oxy-fuel spraying process was used to investigate and improve the surface properties of a workpiece. The research was focused on the spherical surface of a workpiece made of high-strength steel, a ball and socket assembly. After spraying with a nickel alloy, the surface was machined by milling. The coating was carried out as a process in which a very thin layer of coating of the required thickness and the required specific properties, i.e., high Vickers hardness, adhesion to the surface, wear resistance and other important characteristics, which must be respected in other machining methods, was applied to the already finished, heat-prepared metal substrate. This article deals with the milling of complex surfaces of steel substrate EN 10060 after spraying with NiCrBSi alloy. After spraying, a total of 15 milling experiments were performed in order to determine precisely the optimal cutting parameters of milling and surface adhesion, based on newly acquired prediction relations. The main presented results are new relations for the determination of optimal technological milling conditions based on the identification of adhesive sections using derived equations. The new relations were verified and also compared with the current literature in the field.

Turning of Austempered Ductile Iron with ceramic tools

2020 ◽  
pp. 095440542095715 ◽  
Author(s):  
A Fernández-Valdivielso ◽  
LN López de Lacalle ◽  
P Fernández-Lucio ◽  
H González
Keyword(s):  
Heat Treatment ◽  
Tool Wear ◽  
Ductile Iron ◽  
High Strength ◽  
Cutting Parameters ◽  
Precise Determination ◽  
Machining Process ◽  
Austempered Ductile Iron ◽  
Machining Time ◽  
Ceramic Tools

Austempered ductile iron castings (ADI) are characterized by the high strength and resistance to fatigue, impact, and wear. ADI mechanical properties are obtained by performing a heat treatment on ductile iron casting. Thus, the so-called ausferrite microstructure is achieved. However, heat treatment significantly affects ductile casting machinability. A precise determination of ADI microstructure, on the one hand, and to choose correct machining process parameters and tool wear control on the other, are essential to optimize cutting processes and for the introduction of ceramic inserts. Ceramics are an alternative to carbide tools. In this paper, ceramic tools for the dry turning of ADI castings are studied. Thus, different technical ceramics were analyzed, identifying the dominant wear mechanism and evolution. Tool wear rate magnitude was determined indirectly by the variation of cutting force along machining time. Finally, different tests helped to study ceramics wear sensitivity with respect to cutting parameters. Mixed ceramics of Al2O3 with TiC showed the best performance, followed by SiAlON ones.

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