Effect of ball end milling parameters on surface and subsurface of Inconel-718

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.

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

Volume 2: Processing ◽

10.1115/msec2014-4015 ◽

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.

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Optimization of Cutting Parameters for Cutting Force Minimization in Helical Ball End Milling of Inconel 718 by Using Genetic Algorithm

Procedia CIRP ◽

10.1016/j.procir.2018.08.261 ◽

2018 ◽

Vol 77 ◽

pp. 477-480 ◽

Cited By ~ 2

Author(s):

Varsharani Gaikhe ◽

Jambeswar Sahu ◽

Raju Pawade

Keyword(s):

Genetic Algorithm ◽

Cutting Force ◽

Inconel 718 ◽

End Milling ◽

Cutting Parameters ◽

Ball End Milling ◽

Optimization Of Cutting Parameters

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Investigation on Chip Morphology and Surface Quality in High-Speed Ball-End Milling of Inconel 718

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.353 ◽

2010 ◽

Vol 443 ◽

pp. 353-358 ◽

Cited By ~ 1

Author(s):

Harshad A. Sonawane ◽

Suhas S. Joshi

Keyword(s):

Surface Quality ◽

Inconel 718 ◽

High Speed ◽

End Milling ◽

Chip Morphology ◽

Helix Angle ◽

Processing Parameters ◽

Milling Process ◽

Machining Parameters ◽

Ball End Milling

The ball end milling process, commonly used for generating complex shapes, involves continuous variation in the uncut chip dimensions, which depends on the cutter geometry and the machining parameters. The proposed analytical model evaluates the undeformed and the deformed chip dimensions including chip length, width and thickness. The undeformed and deformed chip dimensions, is a function of cutter rotation angle, instantaneous cutter radius, helix angle, and other processing parameters. The surface quality, in the form of surface roughness, during high-speed ball end milling of Inconel 718 is also analysed in this paper.

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