A systemic investigation of tool edge geometries and cutting parameters on cutting forces in turning of Inconel 718

2019 ◽  
Vol 105 (1-4) ◽  
pp. 531-543 ◽  
Author(s):  
Xing Dai ◽  
Kejia Zhuang ◽  
Han Ding
Keyword(s):  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Parameters ◽  
Tool Edge

scholarly journals Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3974 ◽  
Author(s):  
Mohamed Shnfir ◽  
Oluwole A. Olufayo ◽  
Walid Jomaa ◽  
Victor Songmene
Keyword(s):  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Mechanical Shock ◽  
Tool Edge ◽  
Aisi 1045 ◽  
High Feed ◽  
1045 Steel ◽  
Edge Preparation

Intermittent machining using ceramic tools such as hard milling is a challenging task due to the severe mechanical shock that the inserts undergo during machining and the brittleness of ceramic inserts. This study investigates the machinability of hardened steel AISI 1045 during face milling using SiAlON and whisker (SiCW) based ceramic inserts. The main focus seeks to identify the effects of cutting parameters, milling configuration, edge preparation and work material hardness on machinability indicators such as resultant cutting force, power consumption and flank tool wear. The effects of these varying cutting conditions on performance characteristics were investigated using a Taguchi orthogonal array design L32 (21 44) and evaluated using ANOVA. Results indicate lower resultant cutting forces were recorded with honed edge inserts of SiAlON ceramic grade. In addition, a decrease in resultant cutting forces was associated with reduced feed rates and increased hardness. The feed rate and cutting speed were also identified as the greatest influencing factors in the amount of cutting power. The main wear mechanisms responsible for flank wear on the ceramic inserts are micro-scale abrasion and micro-chipping. Increased flank wear was observed at low cutting speed and high feed rates, while micro-chipping mostly ensued from the cyclic loading of the radial tool edge form, which is more susceptible to impact fragmentation. Thus, the use of tools with chamfered tool-edge preparation greatly improved observed wear values. Additional confirmation tests were also conducted to validate the results of the tests.

Statistical Analysis of Cutting Forces in Turning Inconel 718 with Coated Carbide Tools

2010 ◽  
Vol 135 ◽  
pp. 96-101 ◽  
Author(s):  
Xiao Li Zhu ◽  
Song Zhang ◽  
Tong Chao Ding ◽  
Yuan Wei Wang
Keyword(s):  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Regression Equations ◽  
Dry Cutting ◽  
Cutting Force Components ◽  
Optimal Cutting Parameters ◽  
Coated Carbide

The experimental study presented in this paper aims to investigate the effects of cutting parameters on cutting forces, and search the optimal cutting parameters for the minimum cutting forces during turning Inconel 718 under dry cutting conditions. Based on Taguchi method, a L25 (53) array was designed to conduct the turning experiments. The experimental results indicate that the best condition for the minimum cutting force components is the combination of 45m/min cutting speed, 0.08mm/r feed rate, and 0.2mm depth of cut. The effects of the cutting parameters on cutting forces are investigated while employing the analysis of variance (ANOVA). Finally, the quadratic regression equations for cutting forces were formulated, which can well describe the relationship between cutting parameters and cutting forces.

scholarly journals A surrogate-assisted optimization approach for multi-response end milling of aluminum alloy AA3105

2020 ◽  
Vol 111 (9-10) ◽  
pp. 2419-2439
Author(s):  
Tamal Ghosh ◽  
Yi Wang ◽  
Kristian Martinsen ◽  
Kesheng Wang
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Material Removal Rate ◽  
Cutting Forces ◽  
Material Removal ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Data Driven ◽  
Optimal Cutting Parameters

Abstract Optimization of the end milling process is a combinatorial task due to the involvement of a large number of process variables and performance characteristics. Process-specific numerical models or mathematical functions are required for the evaluation of parametric combinations in order to improve the quality of the machined parts and machining time. This problem could be categorized as the offline data-driven optimization problem. For such problems, the surrogate or predictive models are useful, which could be employed to approximate the objective functions for the optimization algorithms. This paper presents a data-driven surrogate-assisted optimizer to model the end mill cutting of aluminum alloy on a desktop milling machine. To facilitate that, material removal rate (MRR), surface roughness (Ra), and cutting forces are considered as the functions of tool diameter, spindle speed, feed rate, and depth of cut. The principal methodology is developed using a Bayesian regularized neural network (surrogate) and a beetle antennae search algorithm (optimizer) to perform the process optimization. The relationships among the process responses are studied using Kohonen’s self-organizing map. The proposed methodology is successfully compared with three different optimization techniques and shown to outperform them with improvements of 40.98% for MRR and 10.56% for Ra. The proposed surrogate-assisted optimization method is prompt and efficient in handling the offline machining data. Finally, the validation has been done using the experimental end milling cutting carried out on aluminum alloy to measure the surface roughness, material removal rate, and cutting forces using dynamometer for the optimal cutting parameters on desktop milling center. From the estimated surface roughness value of 0.4651 μm, the optimal cutting parameters have given a maximum material removal rate of 44.027 mm3/s with less amplitude of cutting force on the workpiece. The obtained test results show that more optimal surface quality and material removal can be achieved with the optimal set of parameters.

Effect of lubrication and cutting parameters on ultrasonically assisted turning of Inconel 718

2005 ◽  
Vol 162-163 ◽  
pp. 649-654 ◽  
Author(s):  
A.V. Mitrofanov ◽  
N. Ahmed ◽  
V.I. Babitsky ◽  
V.V. Silberschmidt
Keyword(s):  
Inconel 718 ◽  
Cutting Parameters

scholarly journals Microstructure characterisation of Inconel 718 after laser assisted turning

2018 ◽  
Vol 188 ◽  
pp. 02004 ◽  
Author(s):  
Tadeusz Chwalczuk ◽  
Damian Przestacki ◽  
Piotr Szablewski ◽  
Agata Felusiak
Keyword(s):  
Inconel 718 ◽  
Laser Heating ◽  
Dendritic Structure ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Optical Microscope ◽  
Depth Of Cut ◽  
Heat Affect Zone ◽  
Molecular Laser ◽  
Laser Assisted Turning

The paper presents the discussion about the possibility of optimising heating and cutting parameters for turning under laser assisted machining (LAM) conditions. The samples of Inconel 718 after annealing and ageing were used. The laser heating experiments were carried out on the stand equipped with the CO2 molecular laser. Characterisation of samples was performed by an optical microscope, hardness measurements, scanning electron microscopy (SEM) to ensure the exact depth of heat affect zone range and to optimised further cutting parameters. Different absorbing layers for laser beam impact improvement were tested. Turning trials were performed with constant cutting speed vc = 28 m/min and feed f = 0,2 mm/rev. The influence of depth of cut ap on microstructure and its properties were investigated. It was proven that for sequential LAM dendritic structure appears in the laser affected zone of the Ni-based alloy. Such microstructures cause better machinability of Inconel 718 due to surface softening.

scholarly journals An experimental research on the machinability of a high temperature titanium alloy BTi-6431S in turning process

2018 ◽  
Vol 5 ◽  
pp. 12
Author(s):  
Yanfeng Gao ◽  
Yongbo Wu ◽  
Jianhua Xiao ◽  
Dong Lu
Keyword(s):  
Titanium Alloy ◽  
High Temperature ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Cutting Forces ◽  
Shear Bands ◽  
Cutting Parameters ◽  
Aircraft Manufacturing ◽  
Mechanical And Physical Properties ◽  
Alpha Titanium

Titanium alloys are extensively applied in the aircraft manufacturing due to their excellent mechanical and physical properties. At present, the α + β alloy Ti6Al4V is the most commonly used titanium alloy in the industry. However, the highest temperature that it can be used only up to 300 °C. BTi-6431S is one of the latest developed high temperature titanium alloys, which belongs to the near-α alloy group and has considerably high tensile strength at 650 °C. This paper investigates the machinability of BTi-6431S in the terms of cutting forces, chip formation and tool wear. The experiments are carried out in a range of cutting parameters and the results had been investigated and analyzed. The investigation shows that: (1) the specific cutting forces in the machining of BTi-6431S alloy are higher than in the machining of Ti6Al4V alloy; (2) the regular saw-tooth chips more easily formed and the shear bands are narrower in the machining of BTi-6431S; (3) SEM and EDS observations of the worn tools indicate that more cobalt elements diffuse into the workpiece from tool inserts during machining of BTi-6431S alloy, which significantly aggravates tool wear rate. The experimental results indicate that the machinability of BTi-6431S near alpha titanium alloy is significantly lower than Ti-6Al-4V alloy.

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