Experimental Investigation into the Effect of Ball End Milling Parameters on Surface Integrity of Inconel 718

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

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Surface Integrity Studies in Ball End Milling of Thin Shaped Cantilever Inconel 718

Volume 2: Processing ◽

10.1115/msec2014-4015 ◽

2014 ◽

Author(s):

Nandkumar N. Bhopale ◽

Raju S. Pawade

Keyword(s):

Surface Integrity ◽

Inconel 718 ◽

Tool Path ◽

Surface Defects ◽

End Milling ◽

Surface Region ◽

Lower Surface ◽

Machined Surface ◽

Ball End Milling ◽

Integrity Analysis

The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever plate of Inconel 718. It is noticed that the workpiece deflection has significantly contributed to machined surface integrity in terms of surface topography and subsurface microhardness. The ball end milling performed with 15° workpiece inclination with horizontal tool path produced higher surface integrity which varies with the location of machined surface region. In general, the mid portion of the machined plate shows lower surface roughness and microhardness with less surface defects.

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Effect of ball end milling parameters on surface and subsurface of Inconel-718

International Journal of Basic and Applied Sciences ◽

10.14419/ijbas.v4i1.3823 ◽

2014 ◽

Vol 4 (1) ◽

pp. 66 ◽

Cited By ~ 1

Author(s):

Nandkumar Bhopale ◽

Raju Pawade

Keyword(s):

Inconel 718 ◽

End Milling ◽

Ball End Milling ◽

Milling Parameters

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Experimental Investigation on Surface Integrity of End Milling Nickel Based Alloy-Inconel 718

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.500.51 ◽

2012 ◽

Vol 500 ◽

pp. 51-57 ◽

Cited By ~ 2

Author(s):

Xiao Jiang Cai ◽

Sheng Qin ◽

Qing Long An ◽

Ming Chen

Keyword(s):

Experimental Investigation ◽

Residual Stresses ◽

Surface Topography ◽

Surface Integrity ◽

Inconel 718 ◽

High Speed ◽

End Milling ◽

Cutting Speed ◽

Cutting Parameters ◽

Machine Material

nconel 718 is a typical difficult-to-machine material, and its high speed end milling process has wide applications in manufacturing parts for aerospace and power industry. Surface integrity of these parts greatly influences the final characteristics. This paper presents an experimental investigation to evaluate surface integrity behaviors of Inconel 718 with finishing cutting parameters in terms of surface topography, surface roughness Ra, residual stresses and subsurface microstructure and microhardness. The results show that high cutting speed is advisable to get better surface topography and roughness. Residual stresses and subsurface microhardness barely increase after 80m/min. Microstructure in surface layer has only slight deformation after high speed milling.

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