Simulation of the chip morphology together with its evolution in machining of Inconel 718 by considering widely spread cutting speed

2021 ◽  
Author(s):  
Chun Liu ◽  
Min Wan ◽  
Yun Yang
Keyword(s):  
Inconel 718 ◽  
Cutting Speed ◽  
Chip Morphology

Experimental Investigations on Orthogonal Turning of Inconel 718 with TiAlN Coated Tool

2020 ◽  
Vol 979 ◽  
pp. 142-148
Author(s):  
K. Gobivel ◽  
K.S. Vijay Sekar ◽  
G. Prabhakaran ◽  
R. Sugin Elankavi
Keyword(s):  
Surface Integrity ◽  
Inconel 718 ◽  
Deformation Behaviour ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Experimental Investigations ◽  
Orthogonal Turning ◽  
Coated Tool ◽  
Utmost Care ◽  
Proper Material

Inconel 718 is a nickel-based super alloy well suited for high-temperature applications encountered in space shuttles, aircraft black box and turbocharger due to their inherent properties. Taking into account of extreme working conditions, efficiency in the process of machining without affecting the nature of the surface integrity with utmost care assumes a lot of importance. In this current study, an attempt has been made to investigate the influence of cutting speed and feed rate on various machining aspects like cutting forces, chip morphology, surface roughness and tool wear during the orthogonal turning of Inconel 718. Also, the work has been focused on feed forces and thrust forces to understand the proper material deformation behaviour and surface integrity.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

Thermal-Mechanical Effect on Temperature/Stress Distribution when Orthogonal Cutting Bearing Steel

2009 ◽  
Vol 407-408 ◽  
pp. 420-423
Author(s):  
He Ping Wang ◽  
Xue Ping Zhang
Keyword(s):  
Stress Distribution ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Bearing Steel ◽  
Mechanical Effect ◽  
Arbitrary Lagrangian Eulerian ◽  
Calculation Results ◽  
On Chip ◽  
Explicit Dynamic

An explicit dynamic coupled thermal-mechanical Arbitrary Lagrangian Eulerian (ALE) model was established to simulate orthogonal cutting AISI 52100 bearing steel, and its temperature and stress distribution. Based on ABAQUS, The ALE approach effectively simulates plastic flow around round edge of the cutting tool without employing chip separation criteria. The calculation results reveal that cutting speed and cutting depth have great impact on chip morphology, stress and temperature distribution in the finished surface and subsurface, the predicted temperature agrees well with experiment data obtained under the similar cutting conditions as well as the change in chip morphology from continuous to sawtooth as the cutting speed increases.

scholarly journals Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

2018 ◽  
Vol 2 (3) ◽  
pp. 50 ◽  
Author(s):  
Hussien Hegab ◽  
Hossam Kishawy
Keyword(s):  
Inconel 718 ◽  
Government Regulation ◽  
Effective Properties ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Al2o3 Nanoparticles ◽  
Machining Performance ◽  
Multi Wall Carbon Nanotubes ◽  
Minimum Quantity ◽  
Cooling And Lubrication

Difficult-to-cut materials have been widely employed in many engineering applications, including automotive and aeronautical designs because of their effective properties. However, other characteristics; for example, high hardness and low thermal conductivity has negatively affected the induced surface quality and tool life, and consequently the overall machinability of such materials. Inconel 718, is widely used in many industries including aerospace; however, the high temperature generated during machining is negatively affecting its machinability. Flood cooling is a commonly used remedy to improve machinability problems; however, government regulation has called for further alternatives to reduce the environmental and health impacts of flood cooling. This work aimed to investigate the influence of dispersed multi-wall carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles, on enhancing the minimum quantity lubrication (MQL) technique cooling and lubrication capabilities during turning of Inconel 718. Machining tests were conducted, the generated surfaces were examined, and the energy consumption data were recorded. The study was conducted under different design variables including cutting speed, percentage of added nano-additives (wt.%), and feed velocity. The study revealed that the nano-fluids usage, generally improved the machining performance when cutting Inconel 718. In addition, it was shown that the nanotubes additives provided better improvements than Al2O3 nanoparticles.

scholarly journals Milling Inconel 718 Workpiece With Cryogenically Treated And Untreated Cutting Tools

2021 ◽  
Author(s):  
Hüseyin Gürbüz ◽  
Şehmus Baday
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Abrasive Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Tool Wear ◽  
Feed Force

Abstract Although Inconel 718 is an important material for modern aircraft and aerospace, it is a kind material, which is known to have low machinability. Especially, while these types of materials are machined, high cutting temperatures, BUE on cutting tool, high cutting forces and work hardening occur. Therefore, in recent years, instead of producing new cutting tools that can withstand these difficult conditions, cryogenic process, which is a heat treatment method to increase the wear resistance and hardness of the cutting tool, has been applied. In this experimental study, feed force, surface roughness, vibration, cutting tool wear, hardness and abrasive wear values that occurred as a result of milling of Inconel 718 material by means of cryogenically treated and untreated cutting tools were investigated. Three different cutting speeds (35-45-55 m/min) and three different feed rates (0.02-0.03-0.04 mm/tooth) at constant depth of cut (0.2 mm) were used as cutting parameters in the experiments. As a result of the experiments, lower feed forces, surface roughness, vibration and cutting tool wear were obtained with cryogenically treated cutting tools. As the feed rate and cutting speed were increased, it was seen that surface roughness, vibration and feed force values increased. At the end of the experiments, it was established that there was a significant relation between vibration and surface roughness. However, there appeared an inverse proportion between abrasive wear and hardness values. While BUE did not occur during cryogenically treated cutting tools, it was observed that BUE occurred in cutting tools which were not cryogenically treated.

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.

Machining of Hastelloy-X Based on Finite Element Modelling

2018 ◽  
Vol 30 ◽  
pp. 1-7 ◽  
Author(s):  
Fatih Hayati Çakır ◽  
Mehmet Alper Sofuoğlu ◽  
Selim Gürgen
Keyword(s):  
Finite Element ◽  
High Temperature ◽  
Numerical Model ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Material Model ◽  
High Temperature Strength ◽  
Hastelloy X ◽  
Turning Operation

Nickel-based alloys provide high corrosion resistance and high-temperature strength but these alloys possess poor machinability. Hastelloy-X is a nickel based alloy that has been used for high temperature use. There are many studies about finite element modeling of aerospace alloys but studies in literature with Hastelloy-X are limited. In the present work, machining characteristics of Hastelloy-X were investigated and a numerical model was developed for the turning operation of Hastelloy-X. Two input parameters (cutting speed and feed rate) were variated in the operations and the results were evaluated considering process outputs such as cutting forces, cutting temperature, effective stresses and chip morphology. Based on the verification of the numerical model using experimental results, presented material model is appropriate for the turning operation of Hastelloy-X at low and medium cutting speed machining conditions.

scholarly journals Chip Morphology and Delamination Characterization for Vibration-Assisted Drilling of Carbon Fiber-Reinforced Polymer

2019 ◽  
Vol 3 (1) ◽  
pp. 23 ◽  
Author(s):  
Ramy Hussein ◽  
Ahmad Sadek ◽  
Mohamed Elbestawi ◽  
M. Attia
Keyword(s):  
Carbon Fiber ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Polymers ◽  
Geometrical Accuracy ◽  
Carbon Fiber Reinforced

Carbon fiber-reinforced polymers (CFRP) are widely used in the aerospace industry. A new generation of aircraft is being built using CFRP for up to 50% of their total weight, to achieve higher performance. Exit delamination and surface integrity are significant challenges reported during conventional drilling. Exit delamination influences the mechanical properties of machined parts and, consequently, reduces fatigue life. Vibration-assisted drilling (VAD) has much potential to overcome these challenges. This study is aimed at investigating exit delamination and geometrical accuracy during VAD at both low- and high-frequency ranges. The kinematics of VAD are used to investigate the relationship between the input parameters (cutting speed, feed, vibration frequency, and amplitude) and the uncut chip thickness. Exit delamination and geometrical accuracy are then evaluated in terms of mechanical and thermal load. The results show a 31% reduction in cutting temperature, as well as a significant enhancement in exit delamination, by using the VAD technology.

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