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

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.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

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.

Surface quality analysis in ball end milling of Inconel 718 cantilevers by response surface methodology

2016 ◽  
Vol 231 (4) ◽  
pp. 628-640 ◽  
Author(s):  
Nandkumar N Bhopale ◽  
Raju S Pawade ◽  
Suhas S Joshi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Machining Parameters ◽  
Machined Surface ◽  
Ball End Milling ◽  
Fixed End ◽  
Side Flow

The ball end milling process is commonly used for generating complex three-dimensional sculptured surfaces with definite curvature. In such cases, variation of surface properties along with the machined surface is not well understood. Therefore, this article investigates the effect of machining parameters on the quality of surface in ball end milling of thin-shaped cantilever of Inconel 718. A distinct variation is also observed in the measured values of deflection of workpiece: surface roughness and surface damage in different regions, that is, fixed end, mid portion and free end of machined surface. The experiments were conducted according to the central composite design with four factors, namely, cutting speed, feed, workpiece thickness and workpiece inclination with tool path orientation. It is observed that the process parameters have statistically significant effect on machined surface of Inconel 718. Horizontal tool path condition during milling is most favourable in all aspects of surface quality with high speed and lower feed. The surface roughness values at the fixed end of plate are less as compared with that of mid portion and free end sides. Scanning electron microscope images show various defects such as side flow, smeared layer, microparticle, grooves and feed marks.

scholarly journals Experimental Study on Surface Integrity of Titanium Alloy Ti6Al4V by Ball End Milling

2018 ◽  
Vol 14 (1) ◽  
pp. 115-121 ◽  
Author(s):  
Pun Krishna Kaway ◽  
Xueping Zhang
Keyword(s):  
Titanium Alloy ◽  
Surface Integrity ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Ball End Milling ◽  
Titanium Alloy Ti6al4v ◽  
Cutting Speeds

Titanium alloy, Ti6Al4V, has been widely used in aerospace, automotive, biomedical, and chemical industries due to its exceptional strength to weight ratio, high temperature performance, and corrosion resistance. However, machinability of Ti6Al4V is poor due to high strength at elevated temperatures, low modulus, and low thermal conductivity. Poor machinability of Ti6Al4V deteriorates the surface integrity of the machined surface. Poor surface integrity causes high machining cost, surface defects, initiate cracks, and premature failure of the machined surface. Thus, it is indispensable to obtain better surface integrity when machining titanium alloy Ti6Al4V. Cutting parameters such as cutting speed, feed rate, and depth of cut have significant effect on the surface integrity when machining titanium alloy Ti6Al4V. Hence, this study investigates surface integrity of Ti6Al4V by ball end milling at different cutting speeds, feed rates, and depth of cuts. Microstructure of subsurface is studied at different cutting speeds, feed rates, and depth of cuts. The results show that the depth of deformation of subsurface increases with increase in the cutting speed, feed rate, and depth of cut. Journal of the Institute of Engineering, 2018, 14(1): 115-121

scholarly journals The Surface Integrity of Titanium Alloy When Using Micro-Textured Ball-End Milling Cutters

Micromachines ◽  
2018 ◽  
Vol 10 (1) ◽  
pp. 21 ◽  
Author(s):  
Shucai Yang ◽  
Song Yu ◽  
Chunsheng He
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Work Hardening ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Surface Machining ◽  
Ball End Milling

Processing certain kinds of micro-textures onto the surface of tools can improve their wear resistance, reduce the friction between them and machined surfaces, prolong their service life and improve their processing efficiency. When milling titanium alloy with ball-end milling cutters, the cutting force and the cutting heat causes plastic deformation and a concentration of stress on workpiece surfaces, damaging their surface integrity. In this paper, we report on a test involving the milling of titanium alloy, where a micro-texture was placed onto the front of a ball-end cutter and the surface roughness and work hardening of the machined surface were studied. The orthogonal experiment was designed around changes in the diameter of the micro-texture, its depth, the spacing between individual micro-pits, and its distance from the cutting edge. Data from the experiment was then used to assess the influence changes in the micro-texture parameters had upon the roughness and hardening of the surface. The data was processed and analyzed by using regression analysis and a prediction model for surface roughness and work hardening was established. The reliability of the model was then verified. The contents of this paper provide a theoretical basis for improving the cutting performance and the surface machining quality of cemented carbide tools.

Surface integrity analysis of machined Inconel 718 over multiple length scales

CIRP Annals ◽  
2012 ◽  
Vol 61 (1) ◽  
pp. 99-102 ◽  
Author(s):  
Rachid M'Saoubi ◽  
Tommy Larsson ◽  
José Outeiro ◽  
Yang Guo ◽  
Sergey Suslov ◽  
...  
Keyword(s):  
Surface Integrity ◽  
Inconel 718 ◽  
Length Scales ◽  
Multiple Length Scales ◽  
Integrity Analysis
Sign in / Sign up

Export Citation Format

Share Document