EFFECT OF CUTTING PARAMETERS ON CUTTING ZONE IN CRYOGENIC HIGH SPEED MILLING OF INCONEL 718 ALLOY

2015 ◽  
Vol 77 (27) ◽  
Author(s):  
A. H. Musfirah ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Part Quality ◽  
Cutting Zone ◽  
Coated Carbide

In tribology phenomenon, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in ball end milling process. Experiments were performed using a multi-layer TiAlN/AlCrN-coated carbide inserts under cryogenic and dry cutting condition. A transient milling simulation model using Third Wave Advantedge has been done in order to gain in-depth understanding of the thermomechanical aspects of machining and their influence on resulted part quality. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can  decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining. Furthermore, the microstructure of machined workpiece revealed that cryogenic cooling also can reduce a plastic deformation at the cutting surface as compared with the dry machining. 

Tribological Characterization of the Cutting Zone in Milling Nickel Based Alloy

2014 ◽  
Vol 554 ◽  
pp. 12-16 ◽  
Author(s):  
Musfirah Abdul Hadi ◽  
Jaharah A. Ghani ◽  
C.H. Che Haron ◽  
Natasha A. Raof
Keyword(s):  
Surface Roughness ◽  
Physical Vapor Deposition ◽  
Cutting Temperature ◽  
Cryogenic Cooling ◽  
Cutting Condition ◽  
Dry Machining ◽  
Cutting Zone ◽  
Tribological Characterization ◽  
Coated Carbide

In the area of tribology, surface roughness has become one of the most important factors that contributed to the evaluation of part quality during machining operation. In order to understand the behavior of cryogenic cooling assistance in machining Inconel 718, this paper aims to provide better understanding of tribological characterization of liquid nitrogen near the cutting zone of this material in milling process. Experiments were performed using physical vapor deposition (PVD) - coated carbide inserts under cryogenic and dry cutting condition. The cryogenic results of the cutting temperature, cutting forces and surface roughness of the ball nose cutting tool have been compared with those of dry machining. Finally, experimental results proved that cryogenic implementation can decrease the amount of heat transferred to the tool up to almost 70% and improve the surface roughness to a maximum of 31% when compared with dry machining.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

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.

Effects of Liquid Nitrogen on Cryogenic Machining of Aisi D2 Hardened Steel

2011 ◽  
Vol 335-336 ◽  
pp. 400-405
Author(s):  
Samraj Ravi ◽  
Murugasan Pradeep Kumar
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Liquid Nitrogen ◽  
Cutting Temperature ◽  
Hardened Steel ◽  
Cryogenic Machining ◽  
Workpiece Surface ◽  
Aisi D2 ◽  
Cutting Zone ◽  
Coated Carbide

The milling of hardened steel generates very high temperature in the cutting zone, and leads to detrimental effects on the cutting force, workpiece surface finish and tool life. Cryogenic machining is an environmental friendly new approach for the desirable control of the cutting temperature in the cutting zone. The present work investigates the effect of cryogenic cooling by liquid nitrogen (LN2) on the cutting temperature, cutting force and workpiece surface roughness on the end milling of AISI D2 steel by CVD TiN coated carbide insert, at a constant cutting speed of 100 m/min and varying feed rate in the range of 0.01-0.02 mm/tooth. The experimental results showed that with LN2 as a coolant the cutting force and workpiece surface roughness were reduced compared to dry and wet machining due to the better lubrication and cooling effect through reduction of cutting zone temperature.

Performance evaluation of graphene added nanofluids and self-lubricating tools in machining Inconel 718

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Amrita Maddamasetty ◽  
Kamesh Bodduru ◽  
Siva Bevara ◽  
Rukmini Srikant Revuru ◽  
Sanjay Kumar
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Solid Lubricant ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Fluid ◽  
Superior Performance ◽  
Dry Machining ◽  
Inconel 718 Alloy ◽  
Content Type

Purpose Inconel 718 is difficult to machine due to its high toughness and study hardenability. Though the use of cutting fluids alleviates the problem, it is not sustainable. So, supply of a small quantity of specialized coolant to the machining zone or use of a solid lubricant is a possible solution. The purpose of the present work is to improve machinability of Inconel718 using graphene nanoplatelets. Design/methodology/approach In the present study, graphene is used in the machining of Inconel 718 alloy. Graphene is applied in the following two forms: as a solid lubricant and as an inclusion in cutting fluid. Graphene-based self-lubricating tool and graphene added nanofluids are prepared and applied to turning of Inconel 718 at varying cutting velocities. Performances are compared by measuring cutting forces, cutting temperature, tool wear and surface roughness. Findings Graphene, in both forms, showed superior performance compared to dry machining. In total, 0.3 Wt.% graphene added nanofluids showed the lowest cutting tool temperature and flank wear with 44.95% and 83.37% decrease, respectively, compared to dry machining and lowest surface roughness, 0.424 times compared to dry machining at 87 m/min. Originality/value Graphene could improve the machinability of Inconel 718 when used in tools as a solid lubricant and also when used as a dispersant in cutting fluid. Graphene used as a dispersant in cutting fluid is found to be more effective.

Optimal Cutting Parameters for Desired Surface Roughness in End Milling Inconel 718

2010 ◽  
Vol 126-128 ◽  
pp. 911-916 ◽  
Author(s):  
Yuan Wei Wang ◽  
Song Zhang ◽  
Jian Feng Li ◽  
Tong Chao Ding
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Exponential Regression Model ◽  
Optimal Cutting Parameters ◽  
Coated Carbide

In this paper, Taguchi method was applied to design the cutting experiments when end milling Inconel 718 with the TiAlN-TiN coated carbide inserts. The signal-to-noise (S/N) ratio are employed to study the effects of cutting parameters (cutting speed, feed per tooth, radial depth of cut, and axial depth of cut) on surface roughness, and the optimal combination of the cutting parameters for the desired surface roughness is obtained. An exponential regression model for the surface roughness is formulated based on the experimental results. Finally, the verification tests show that surface roughness generated by the optimal cutting parameters is really the minimum value, and there is a good agreement between the predictive results and experimental measurements.

scholarly journals Tool Life and Surface Roughness of A390 Aluminum Alloy in Milling Process Under Dry and Cryogenic Conditions

2018 ◽  
Vol 7 (4.36) ◽  
pp. 432
Author(s):  
K. Othman ◽  
J. A.Ghani ◽  
J. Afifah ◽  
H. A.Rahman ◽  
C. H.Haron ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Life ◽  
Weight Ratio ◽  
Cryogenic Cooling ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Radial Depth ◽  
Coated Carbide ◽  
Cryogenic Conditions

Aluminum alloy is a lightweight material with high strength-to-weight ratio, low thermal expansion, excellent castability and is applied for heavy wear applications. Recent trends in machining research aimed for improving process and product performance by understand the effect of different cooling/lubrication techniques on machining execution. The milling of A390 Al-Si alloy under dry and cryogenic conditions was investigated and liquid nitrogen (LN2) was used as the cryogenic media. The experimental trial were performance with cutting speeds at 250-350 m/min, feed rates at 0.02-0.04 mm/tooth, radial depth of cut at 12.5-25 mm, and the axial depth of cut was kept constant at 0.3 mm using a coated carbide cutting insert. The results outcomes indicate, an application of cryogenic machining had improved the surface roughness, and there was higher tool life as compared to dry cutting condition. The utilization of cryogenic cooling technique had increased the tool life more than 50% and improved the surface roughness more than 40% as compared with dry condition. It is suggested to the machining industry to consider the application of LN2 as the cryogenic media to have better machinability in machining A390 Al-Si alloy.   

Investigation on Effect of Machining Parameters of End Milling on Surface Finish and Temperature Using Taguchi Technique

2016 ◽  
Vol 16 (4) ◽  
pp. 255-261
Author(s):  
Tamiloli N ◽  
Venkatesan J
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Milling Process ◽  
Machining Parameters ◽  
Cutting Zone ◽  
Machining Optimization ◽  
Quality Surface

AbstractMachining of alloy materials at high cutting speeds produces high temperatures in the cutting zone, which affects the surface quality. Thus, developing a model for estimating the cutting parameters and optimizing this model to minimize the surface roughness and cutting temperatures becomes utmost important to avoid any damage to the quality surface. This paper presents the development of new models and optimizing these models of machining parameters to minimize the surface roughness and cutting temperature in end milling process by Taguchi method with the statistical approach. Two objectives have been considered, minimum arithmetic mean roughness (Ra) and cutting temperature. Due to the complexity of this machining optimization problem, a single objective Taguchi method has been applied to resolve the problem, and the results have been analyzed.

Prediction of Surface Roughness on CNC Turning Based on Monitoring of Cutting Force and Cutting Temperature

2013 ◽  
Vol 690-693 ◽  
pp. 2540-2549 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Cnc Turning ◽  
Roughness Model ◽  
Developed Surface ◽  
Coated Carbide

This paper presents the surface roughness model which is proposed and developed to predict the surface roughness in the CNC turning of the carbon steel with the coated carbide tool under various cutting conditions by using the response surface analysis with the Box-Behnken design based on the experimental results. The in-process monitoring of the cutting force and the cutting temperature is utilized to analyze the relation between the surface roughness and the cutting condition. The tool dynamometer and the infrared pyrometer are employed and installed on the turret of CNC turning machine to measure the in-process cutting force and cutting temperature. The models of cutting force ratio and cutting temperature are also developed based on the experimental data. The optimum cutting condition is determined referring to the minimum surface roughness of the surface plot, which is obtained from the developed surface roughness model. The experimental results show that the higher cutting speed gives the better surface roughness due to the higher cutting temperature, however the tool life becomes shorter. The feed rate is the most significant factor which affects the surface roughness, while a small depth of cut helps to improve the surface roughness. The effectiveness of the surface roughness prediction model has been proved by utilizing an analysis of variance (ANOVA) at 95% confident level. Hence, the surface roughness can be predicted and obtained easily referring to the developed surface roughness model.

Development of Surface Roughness Prediction for Steel in CNC Turning by Using Response Surface Method

2011 ◽  
Vol 335-336 ◽  
pp. 921-926
Author(s):  
Siriwan Chanphong ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Response Surface ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Plain Carbon Steel ◽  
Cutting Condition ◽  
Surface Roughness Prediction ◽  
Roughness Prediction ◽  
Coated Carbide

This research presents the development of the surface roughness prediction in the turning process of the plain carbon steel with the coated carbide tool by using the response surface analysis with the Box-Behnken design. The effects of cutting parameters on the cutting force and the cutting temperature are investigated. The cutting force and the cutting temperature are measured to help analyze the relation between the surface roughness and the cutting conditions. The models of cutting force ratio and the cutting temperature are also proposed based on the experimental data. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

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