scholarly journals Performance of Castor Oil and Neem Oil as Metal Cutting Fluids in Drilling Inconel 718 Using MQL Technique on Tool Wear and Surface Roughness

2021 ◽  
Vol 2129 (1) ◽  
pp. 012070
Author(s):  
Syahilia Syahira Safie ◽  
Muhamad Nasir Murad ◽  
Tan Chye Lih
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inconel 718 ◽  
Castor Oil ◽  
Metal Cutting ◽  
Elevated Temperatures ◽  
High Hardness ◽  
High Strength ◽  
Cutting Fluids ◽  
Neem Oil

Abstract Inconel 718 is hard to cut material due to its high hardness, high strength at elevated temperatures, low thermal diffusivity and affinity to react with tool materials. The high temperature during machining results in aggressive tool wear and poor hole quality. Therefore, the application of metal cutting fluids (MCF) as a lubricating and cooling agent is very significant in the drilling of nickel-based superalloys such as Inconel 718. The present study embraces these issues by evaluating the performance of non-edible vegetable oils such as castor and neem oil under minimal quantity lubrication (MQL) conditions towards the tool wear and surface roughness. The drilling experiments were carried out using coated (TiAlN) carbide drill with diameter of 6 mm at different cutting speeds of 10 and 20 m/min and a constant feed of 0.015 mm/rev. The results of this study showed that castor oil significantly outperformed the neem oil in drilling performance regarding tool wear and surface roughness.

scholarly journals Tool wear estimation in turning of Inconel 718 based on wavelet sensor signal analysis and machine learning paradigms

2020 ◽  
Vol 14 (5-6) ◽  
pp. 693-705
Author(s):  
Tiziana Segreto ◽  
Doriana D’Addona ◽  
Roberto Teti
Keyword(s):  
Machine Learning ◽  
Tool Wear ◽  
Inconel 718 ◽  
Signal Analysis ◽  
Elevated Temperatures ◽  
Wavelet Packet ◽  
Research Work ◽  
High Strength ◽  
Signal Features ◽  
Tool Wear Estimation

AbstractIn the last years, hard-to-machine nickel-based alloys have been widely employed in the aerospace industry for their properties of high strength, excellent resistance to corrosion and oxidation, and long creep life at elevated temperatures. As the machinability of these materials is quite low due to high cutting forces, high temperature development and strong work hardening, during machining the cutting tool conditions tend to rapidly deteriorate. Thus, tool health monitoring systems are highly desired to improve tool life and increase productivity. This research work focuses on tool wear estimation during turning of Inconel 718 using wavelet packet transform (WPT) signal analysis and machine learning paradigms. A multiple sensor monitoring system, based on the detection of cutting force, acoustic emission and vibration acceleration signals, was employed during experimental turning trials. The detected sensor signals were subjected to WPT decomposition to extract diverse signal features. The most relevant features were then selected, using correlation measurements, in order to be utilized in artificial neural network based machine learning paradigms for tool wear estimation.

Influence of cryogenic treatment of cutting tool inserts on tool wear and surface roughness during milling of Inconel 718

2020 ◽  
Author(s):  
Ivan Sunit Rout ◽  
P. Pal Pandian ◽  
Manish Mathew ◽  
Kevin Lobo Ivan ◽  
Shomyajit Misra
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cryogenic Treatment

Investigations of Tool Wear with Water Vapor as Coolant and Lubricant in Green Cutting

2011 ◽  
Vol 317-319 ◽  
pp. 556-559
Author(s):  
Yue Zhang ◽  
Tong Jiang ◽  
Li Han ◽  
Qi Dong Li ◽  
Tai Li Sun ◽  
...  
Keyword(s):  
Water Vapor ◽  
Tool Wear ◽  
Metal Cutting ◽  
Boundary Layer Theory ◽  
Cutting Fluids ◽  
Potential Solution ◽  
Dry Cutting ◽  
Lubricating Film ◽  
Study Results ◽  
Generating System

Green cutting is one of the developing tends in the industry field. Water vapor can be introduced in metal cutting as coolant and lubricant due to its pollution-free, generating easily and unneeded disposal. Therefore, a special generating system is developed to produce suitable water vapor, and a simulation to the velocity of water vapor jet flow is presented. Then tool wear was investigated and a new capillary model is proposed, based on the experimental results. According to the boundary-layer theory, the kinetics equations of flow were solute. The velocity and flux of molecule are presented. In the capillary, the adsorption of tool-chip interface results in boundary lubricating film; the conical shape of capillary limits the depth of coolant and lubricant penetrating; and the negative press is the motility for coolant and lubricant penetrating. The study results show water vapor can decrease tool wear about 10% times and 20% comparing to cutting fluids and dry cutting, and water vapor could be a potential solution of green cutting.

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.

ASSESSING THE TRIBOLOGICAL PROPERTIES OF VEGETABLE OIL EMULSIONS AND MACHINING PARAMETER OPTIMIZATION USING RESPONSE SURFACE METHODOLOGY

2021 ◽  
Author(s):  
D. K. KARUPANNASAMY ◽  
M. SAMBATHKUMAR ◽  
R. GUKENDRAN ◽  
K. S. K. SASIKUMAR ◽  
N. BAASKARAN ◽  
...  
Keyword(s):  
Response Surface Methodology ◽  
Tool Wear ◽  
Response Surface ◽  
Surface Finish ◽  
Castor Oil ◽  
Mineral Oil ◽  
Machining Process ◽  
Neem Oil ◽  
Machining Performance ◽  
Oil Emulsions

Bio-degradable lubricants are the need for industries to promote eco-friendly manufacturing process and protect the workers from health hazards. In this paper, the use of oil–water emulsions from the bio-substitute oils have been formulated and its process parameter on a machining process are optimized using response surface methodology. The emulsions are prepared from the vegetable oils such as castor, mahua, palm and neem oil with polysorbate as emulsifying agent. The friction and wear characteristics are studied with a standard pin on disc tribometer for all the emulsions prepared with the base oils namely castor, mahua and palm oil. From the tribological characterization tests, the castor oil emulsions have shown better performance and stability in comparison to other oils. Hence, castor oil emulsions have been tested for its machining performance studies against a conventional mineral oil emulsion in a turning process. Further, an emulsion based on castor oil and neem oil have been tested for tool wear to utilize the antimicrobial properties of neem oil for reducing the bio fouling effects. The machining performance is indicated based on the surface finish and tool wear. Response surface methodology have been used for optimization of the machining parameters, such as cutting velocity, feed rate and depth of cut to achieve an optimal surface finish for a maximum material removal rate. The results show that the castor oil based emulsion can be used as an excellent alternative for mineral oil emulsions.

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%.

A Two-Parameter Method to Monitor and Characterize Tool Wear in End Milling Inconel 718

2012 ◽  
Author(s):  
W. Li ◽  
Y. B. Guo
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Elevated Temperatures ◽  
Flank Wear ◽  
End Milling ◽  
Parameter Method ◽  
Manufacturing Cost ◽  
Cnc Machine ◽  
Coated Carbide ◽  
Two Parameter

Inconel 718 is among the most widely used superalloys in many industries. It is often used in very harsh conditions such as jet engines, combustors and nuclear reactors due to its high strength at elevated temperatures, high oxidation and corrosion resistance. Machining superalloy Inconel 718 has always been a challenging task due to its poor machinability including rapid work hardening, low thermal conductivity, and relatively short cutting tool life. The fast tool wear during cutting Inconel 718 results in longer production time, deteriorated surface integrity, and higher manufacturing cost. In this paper, an on-line optical tool monitoring system integrated with a CNC machine tool has been developed to examine tool wear evolutions in end milling Inconel 718 with PVD (Ti, Al) N/TiN-coated carbide insert. Three basic types of tool wear: flank wear, nose wear, and crater wear were examined and analyzed. A two-parameter method has been proposed to evaluate both flank wear and nose wear vs. cutting time.

Next Generation Insert for Forced Coolant Application in Machining of Inconel 718

2016 ◽  
Vol 836-837 ◽  
pp. 340-347 ◽  
Author(s):  
Nageswaran Tamil Alagan ◽  
Tomas Beno ◽  
Anders Wretland
Keyword(s):  
Tool Wear ◽  
Surface Area ◽  
Inconel 718 ◽  
Material Removal ◽  
Metal Cutting ◽  
Heat Dissipation ◽  
Catastrophic Failure ◽  
Mass Ratio ◽  
Next Generation ◽  
Primary Focus

Machining technology has undergone an extensive evolution throughout the last decades in its capability to machine hard-to-cut material. This paper will discuss about the next generation insert with cooling feature coupled with forced coolant in machining Inconel 718. The geometry of the insert was changed in a way which has enlarged the surface area approximately 12% compared to regular insert named as nusselt insert. The idea applied in “nusselt insert” was the relation of increase in surface area to heat dissipation. Forced coolant application has become a way to improve existing metal cutting concepts and improve their current material removal rates without any need for a reengineered machining process.Experiments conducted on the inserts is that the first experiment of its kind in machining technology together with forced coolant and tested in four different inserts. The primary focus of the work was the investigation of the relation between the heat dissipation with an increase in surface area/mass ratio in the cutting interface based on its influence on tool wear. The experimental results showed the nusselt insert have better ability for heat dissipation which has led to significant reduce in tool wear and successfully facing Inconel 718 at vc 105 m/min, f 0.3 mm/rev and ap 1 mm where the regular insert had a catastrophic failure at vc 90 m/min, f 0.1 mm/rev and ap 1 mm. Nusselt insert has shown to increase MRR significantly compared to regular insert.

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