scholarly journals Optimization of machining parameters in turning of Inconel 718 Nickel-base super alloy

2020 ◽  
Vol 21 (2) ◽  
pp. 203 ◽  
Author(s):  
Wassila Frifita ◽  
Sahbi Ben Salem ◽  
Abdelkrim Haddad ◽  
Mohamed Athmane Yallese
Keyword(s):  
Surface Roughness ◽  
Specific Energy ◽  
Inconel 718 ◽  
Gas Turbines ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Wide Range ◽  
Nickel Base ◽  
Cutting Parameters Optimization

The high hardness and low thermal diffusivity along with the tremendous strength at high temperatures has rendered the nickel-base super alloys Inconel 718 one of the most difficult to cut material. It possesses a wide range of applications including aerospace as well as chemical and petrochemical industries, and is primarily used in the manufacture of aircraft gas turbines, space vehicles, nuclear power systems, and medical equipment. The present study is mainly focused on the cutting parameters optimization that leads to minimum surface roughness, cutting force and power, specific energy and maximum productivity during the turning of the molded Inconel 718 using a carbide cutting tool. The analysis of variance (ANOVA) method is applied to identify the cutting parameters that most influence the response criteria, and the response surface methodology (RSM) along with the desirability function (DF) approaches are further used to develop the prediction model that addresses the optimization procedure. The different parameters are considered one at a time in order to evaluate the sensitivity of the response (OFAT). This procedure led to identify the nose radius (rε), the feed rate (f), the depth of cut (ap) and the cutting speed (Vc) as the most significant factors on both the surface roughness and the cutting forces. Furthermore, the product (f × ap) and the cutting speed (Vc) were found to be the most dominant factors on the specific energy.

Effect of Machining Parameters on Surface Integrity in Dry Turning of Inconel 718

2013 ◽  
Vol 634-638 ◽  
pp. 2831-2834
Author(s):  
Xiao Li Zhu ◽  
Jin Fa Zhang ◽  
Wu Jun Chen ◽  
Ji Wen Deng
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Surface Integrity ◽  
Feed Rate ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Diffraction Method ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters

Surface quality including residual stresses and surface roughness due to turning operations in Inconel 718 were studied as a function of cutting speed, feed rate and depth of cut. By means of X-ray radiation diffraction method, the influence of cutting parameters on residual stress was investigated. The results show that dry cutting of Inconel 718 resulted in predominantly tensile residual stresses at the machined surface and the surface roughness increased with the increase of cutting parameters.The effects of the cutting parameters on surface integrity are investigated while employing the range analysis. From these results it was possible to select a combination of cutting speed, feed rate and depth of cut that generate favorable surface characteristics.

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%.

Effects of Machining Parameters on Surface Roughness when Ultra-High Precision Diamond Turning RSA443 Optical Aluminum

2019 ◽  
Vol 287 ◽  
pp. 30-34
Author(s):  
Zwelinzima Mkoko ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Silicon Content ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Turning Process ◽  
Optical Components ◽  
Box Behnken Design ◽  
Factors Influencing

In the globally competitive environment, surface roughness and finer tolerances are becoming stringent and certainly most critical for optical components. The aim of this study is to determine the effects of diamond turning process parameters on surface finish when diamond turning RSA 443 alloy having high silicon content. This alloy is a new grade of aluminum that has a potential to be used for production of various optical components. The experiments were conducted based on the Box-Behnken design with three diamond-turning parameters varied at three levels. A mathematical regression model was developed for predicting surface roughness. Further, the analysis of variance was used to analyze the influence of cutting parameters and their interaction in machining. The developed prediction model reveals that cutting speed and feed rate are the most dominant diamond turning factors influencing surface roughness.

Optimization of Machining Parameters During Turning of Tungsten Heavy Alloys Using Taguchi Analysis

2019 ◽  
Author(s):  
Chithajalu Kiran Sagar ◽  
Amrita Priyadarshini ◽  
Amit Kumar Gupta
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
Metal Removal ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Taguchi Analysis ◽  
Heavy Alloys ◽  
Wide Range ◽  
Tungsten Heavy Alloys ◽  
Machining Parameter

Abstract Tungsten heavy alloys (WHAs) are ideally suited to a wide range of density applications such as counterweights, inertial masses, radiation shielding, sporting goods and ordnance products. Manufacturing of these components essentially require machining to achieve desired finish, dimensions and tolerances However, machining of WHAs are extremely challenging because of higher values of elastic stiffness and hardness. Hence, there is a need to find the right combination of cutting parameters to carry out the machining operations efficiently. In the present work, turning tests are conducted on three different grades of WHAs, namely, 90WHA, 95WHA and 97WHA. Taguchi analysis is carried out to find out the most contributing factor as well as optimum cutting parameters that can give higher metal removal rate (MRR), lower surface roughness and lower cutting forces. It is observed that feed rate is the most prominent factor with percentage contribution varying in the range of 46–61%; whereas cutting speed has least effect on cutting forces, especially for 95WHA and 97WHA. Optimum values of forces, surface roughness and MRR and the corresponding machining parameters to be taken are presented. It is observed that 95W WHA has slightly better machinability as compared to other two grades since it gives highest MRR with lowest cutting forces and surface roughness values. The optimum machining parameter settings, so predicted, can be utilized to machine WHAs efficiently for manufacture of counter weights and inertial masses used in aerospace applications.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

Machining characteristics of Inconel 718 under several cutting conditions based on Taguchi method

2012 ◽  
Vol 227 (9) ◽  
pp. 1889-1897 ◽  
Author(s):  
R Thirumalai ◽  
JS Senthilkumaar ◽  
P Selvarani ◽  
S Ramesh
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Flank Wear ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machining Parameters ◽  
Dry Machining ◽  
Noise Factors

Extensive researchers have conducted several experiments in the past for selecting the optimum parameters in machining nickel based alloy – Inconel 718. These experiments conducted so far are dealt with dry machining and flooded coolant machining of nickel alloy Inconel 718. In this research study, the usage of refrigerated coolant is also dealt with and it is compared with dry machining and flooded coolant machining. Cutting speed, feed and depth of cut are considered as the machining parameters. The effectiveness of the refrigerated coolant in machining the heat resistant super alloy material Inconel 718 with respect to these machining parameters are described in this article. The machinability studies parameters were generated with surface roughness and flank wear. The performance of uncoated carbide cutting tool was investigated at various cutting condition under dry, flooded coolant and refrigerated coolant machining. The relationship between the machining parameters and the performance measures were established and using analysis of variance significant machining parameters determined. This article made an attempt to Taguchi optimization technique to study the machinability performances of Inconel 718. Taguchi approach is an efficient and effective experimental method in which a response variable can be optimized, given various control and noise factors, using fewer experiments than a factorial design. Taguchi’s optimization analysis indicates that the factors level, its significance to influence the surface roughness and flank wear for the machining processes. Confirmation tests were conducted at an optimal condition to make a comparison between the experimental results foreseen from the mentioned correlations.

scholarly journals Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Harun Gokce
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Taguchi Method ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Tool Wear ◽  
Wide Range

Stainless steels with unique corrosion resistance are used in applications with a wide range of fields, especially in the medical, food, and chemical sectors, to maritime and nuclear power plants. The low heat conduction coefficient and the high mechanical properties make the workability of stainless steel materials difficult and cause these materials to be in the class of hard-to-process materials. In this study, suitable cutting tools and cutting parameters were determined by the Taguchi method taking surface roughness and cutting tool wear into milling of Custom 450 martensitic stainless steel. Four different carbide cutting tools, with 40, 80, 120, and 160 m/min cutting speeds and 0.05, 0.1, 0.15, and 0.2 mm/rev feed rates, were selected as cutting parameters for the experiments. Surface roughness values and cutting tool wear amount were determined as a result of the empirical studies. ANOVA was performed to determine the significance levels of the cutting parameters on the measured values. According to ANOVA, while the most effective cutting parameter on surface roughness was the feed rate (% 50.38), the cutting speed (% 81.15) for tool wear was calculated.

Study on Spindle Vibration and Surface Finish in Turning of Al 7075

2017 ◽  
Vol 261 ◽  
pp. 321-327 ◽  
Author(s):  
Abidin Şahinoğlu ◽  
Şener Karabulut ◽  
Abdulkadir Güllü
Keyword(s):  
Surface Roughness ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting ◽  
Al 7075 ◽  
Spindle Vibration ◽  
Coated Cemented Carbide

In this study, the relationship between the spindle vibration and surface roughness was investigated and the effect of the cutting parameters on surface roughness and spindle vibration during the machining of Aluminum alloy 7075 (Al 7075) were determined. Experimental studies have been carried out on a CNC turning machine using coated cemented carbide cutting tools under dry cutting environment. L64 full factorial design of experiments was used to investigate the optimal machining parameters for spindle vibration and surface roughness. The influences of machining parameters on vibration and surface roughness were evaluated by using analysis of variance (ANOVA) and main effect plots. The results revealed that the feed rate was the most effective cutting parameters on spindle vibration and surface roughness. The machine tool vibration amplitude and surface roughness values were significantly increased with increasing cutting feed. The depth of cut and cutting speed have the least effect on the spindle vibration and indicated an insignificant effect on surface roughness. Mathematical equations were developed to predict the vibration and surface roughness values using the regression analysis.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

scholarly journals Optimization of Machining Parameters in Milling Process of Inconel 718 under Surface Roughness Constraints

2021 ◽  
Vol 11 (5) ◽  
pp. 2137 ◽  
Author(s):  
Tian-Yau Wu ◽  
Chi-Chen Lin
Keyword(s):  
Neural Network ◽  
Surface Roughness ◽  
Artificial Neural Network ◽  
Inconel 718 ◽  
Cutting Parameters ◽  
Pso Algorithm ◽  
Milling Process ◽  
Machining Parameters ◽  
Elman Neural Network ◽  
Swarm Optimization

The objective of this research is to investigate the feasibility of utilizing the Elman neural network to predict the surface roughness in the milling process of Inconel 718 and then optimizing the cutting parameters through the particle swarm optimization (PSO) algorithm according to the different surface roughness requirements. The prediction of surface roughness includes the feature extraction of vibration measurements as well as the current signals, the feature selection using correlation analysis and the prediction of surface roughness through the Elman artificial neural network. Based on the prediction model of surface roughness, the cutting parameters were optimized in order to obtain the maximal feed rate according to different surface roughness constraints. The experiment results show that the surface roughness of Inconel 718 can be accurately predicted in the milling process and thereafter the optimal cutting parameter combination can be determined to accelerate the milling process.

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