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.

Machinability Investigation of HSLA Steel in Hard Turning with Coated Ceramic Tool: Assessment, Modeling, Optimization and Economic Aspects

2019 ◽  
Vol 18 (04) ◽  
pp. 625-655 ◽  
Author(s):  
Asutosh Panda ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ceramic Tool ◽  
Life Estimation

The present study addresses the machinability investigation in finish dry hard turning of high strength low alloy steel with coated ceramic tool by considering cutting speed, feed and depth of cut as machining parameters. The technological parameters like surface roughness, flank wear, chip morphology and economical feasibility have been considered to investigate the machinability performances. Twenty seven set of trials according to full factorial design of experiments are performed and analysis of variance, multiple regression method, Taguchi method, desirability function approach and finally Gilbert’s approach are subsequently applied for parametric influence study, mathematical modeling, multi-response optimization, tool life estimation and economic analysis. Results indicated that feed and cutting speed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness and tool flank wear is considered. Abrasions, adhesion followed by plastic deformation have been observed to be the principal wear mechanism for tool life estimation and observed tool life for coated ceramic insert is 47[Formula: see text]min under optimum cutting conditions. The total machining cost per part is ensued to be lower ($0.29 only) as a consequence of higher tool life, reduction in downtime and enhancement in savings, which finds economical benefits in hard turning. The current work demonstrates the substitution of conventional, expensive and slow cylindrical grinding process, and proposes the most expensive CBN tool alternative using coated ceramic tools in hard turning process considering techno-economical and ecological aspects.

scholarly journals Machinability, Modelling and Statistical Analysis of In-Situ Al–Si–TiB2 Composites

2019 ◽  
Vol 3 (1) ◽  
pp. 28 ◽  
Author(s):  
Jimmy Karloopia ◽  
Shaik Mozammil ◽  
Pradeep Jha
Keyword(s):  
Surface Roughness ◽  
Statistical Analysis ◽  
Tool Wear ◽  
Cutting Forces ◽  
Elevated Temperatures ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Conventional Machining

Aluminum and its alloys have numerous applications in manufacturing, aerospace, and automotive industries. At elevated temperatures, they start to fail in fulfilling their roles and functions. Aluminum-based metal matrix composites (MMCs) are good alternatives for metal and alloys due to their excellent properties. However, the conventional machining of several composites shows complications for a number of reasons, such as high tool wear, poor surface roughness, high machining cost, cutting forces, etc. Numerous studies have already been conducted on the machinability of various MMCs, but the machinability of Al–Si–TiB2 composite is still not well studied. It is of utmost importance that several process parameters of conventional machining are precisely controlled as well as optimized. In this study an effort was made to optimize input parameters such as cutting speed, depth of cut, and feed to obtain well-finished final components with the minimum cutting force and tool wear. These progressions are involved with multiple response characteristics, therefore the exploration of an appropriate multi-objective optimization technique was indeed essential. The performance characteristics of cutting forces and surface roughness were considered for optimization of the machining parameters. Analysis of variance (ANOVA) was employed for the optimization and statistical analysis.

scholarly journals Optimization of Machining Parameters on 7075 Aluminum Alloy using Taguchi and ANOVA for Surface Roughness

2020 ◽  
Vol 8 (5) ◽  
pp. 90-95
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Electrical Discharge Machining ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Tool Wear Rate ◽  
Made In

Optimization of the parameter to provide best solution to reduce the tool wear , surface roughness, cutting forces presented using optimization technique .In present work an experimental study is made. In this Taguchi design of experiment methodology for optimization of parameters on 7075Aluminium alloy using tungsten coated electrode . Experiments were conducted based on L27 standard orthogonal array with three processes parameters are cutting speed, feed, depth of cut . Electrical discharge machining is generally calculated on the basis of Surface Roughness (SR),Tool wear rate (TWR) and cutting force (CF) .The ANOVA(Analysis Of Variance) is used to study the performance characteristics in turning operation . ANOVA placed an important role for producing higher roughness . Finally the software ,MINITAB 17 was used and results obtained

Multiobjective Optimization of End Milling HCHCr Using AlCrN PVD Coated Cutters With MOGA and RSMO

2014 ◽  
Author(s):  
Shantisagar K. Biradar ◽  
Geeta S. Lathkar
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Multiobjective Optimization ◽  
End Milling ◽  
Dominant Role ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Depth Of Cut ◽  
Machining Parameters

Here the End milling is studied for optimization of responses such as surface roughness and tool wear while machining HCHCr. These two conflicting responses decide the quality of process; therefore the multiobjective optimization technique is used. The Response Surface Optimizer (RSMO) and Multiobjective Genetic Algorithm (MOGA) were used as the multiobjective optimization techniques. The PVD coating of 2.5 micron AlCrN was used on four flute HSS End milling cutter. Input machining parameters were cutting speed, feed rate, depth of cut and percentage concentration of the solid lubricant MoS2 mixed with SAE-20 base oil. The experimentation was carried out using two level full factorial design concept while ANOVA technique has been used to verify the adequacy of mathematical model. It was found that the cutting speed (V) is having most dominant role on surface roughness and tool wear. The sensitivity analysis was carried out for studying sensitivity of input parameters for the responses.

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 Fuzzy-MOORA Based Optimization of Machining Parameters for Machinability Enhancement of Titanium

2021 ◽  
Vol 8 (2) ◽  
pp. 189-198
Author(s):  
Durwesh Jhodkar ◽  
Akhtar Khan ◽  
Kapil Gupta
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Tool Flank Wear ◽  
Moora Method ◽  
Fuzzy Moora

The aim of this study is to determine the optimal combination of process parameters when machining commercially pure titanium grade 2. The unification of Multi objective optimization based on ratio analysis (MOORA) and fuzzy approach has applied to optimize the process parameters. Three process parameters i.e. cutting speed, tool overhang, and microhardness have been varied at three levels each and a total of twenty seven experiments have been conducted based on Taguchi’s L27 design of experiment technique. Cutting force, tool flank wear, and average surface roughness have been considered a machinability indicators to measure the process performance. Feed rate and depth of cut have been kept constant. Successful optimization is done and results show that machining titanium at higher cutting speed (140 m/min) and higher tool overhang length (65 mm) with medium hardness (1934 HV) results in lower cutting force, tool flank wear, and surface roughness. Outcomes of the present work reveal that the hybrid fuzzy-MOORA method is convincing enough to obtain the best process parameter combination for the best machinability while machining titanium type difficult-to-machine materials.

scholarly journals Effect of Cutting Parameters on Machinability of Hardened AISI 52100 Bearing Steel

2020 ◽  
Vol 3 (1) ◽  
pp. 474-481
Author(s):  
Mohammad Rafighi
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Bearing Steel ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Manufacturing Cost ◽  
Machining Parameters ◽  
Aisi 52100

In this study, the effects of machining parameters, namely feed rate, cutting speed and depth of cut on the surface roughness was investigated experimentally in hard turning of AISI 52100 bearing steel using cubic boron nitride insert under dry cutting condition. Taguchi method was utilized to reduce the number of trials to 9 for saving the time and manufacturing cost. The significant factor on the surface roughness was determined using analysis of variance. Furthermore, the optimum cutting parameter for reducing the surface roughness was obtained. The findings showed that the feed rate has the highest impact on surface roughness among any other cutting parameters, with 88.32% contribution.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

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.

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