Machining Performance Optimization for Electro Discharge Machining of Inconel 625: A Case Experimental Study

Minimum quantity lubrication (MQL) is currently a widely used lubricating technique during machining, in which minimum amount of lubricant in the form of mist is delivered to the machining interface, thus helps to reduce the negative effects caused to the environment and human health. Further, to enhance the productivity of machining process specifically for hard-to-cut materials, nano cutting fluid (suitably mixed nano materials with conventional cutting fluid) is used as an alternative method to conventional lubrication (wet) in MQL. In this study, h-BN nano cutting fluid was formulated with 0.1% vol. concentration of h-BN in conventional cutting fluid (Servo- ‘S’) for NCF-MQL technique and its tribological behaviors on machining(turning) performance of Inconel 625 were studied and compared with other lubricating conditions (dry, wet, MQL conventional). The tribological effects were analyzed in terms of tool wear analysis, chip morphology along with statistical analysis for machined surface and evolved cutting forces during machining. The optimal input machining parameters for experiments were defined by the use of Taguchi and Grey relational based multi response optimization technique. Finally, the tribological study shows that the use of h-BN NCF-MQL is a viable and sustainable option for improving machining performance of hard- to- cut material like Inconel 625.

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Study on Generating Machining Performance of Two-Dimensional Ultrasonic Vibration-Composited Electrolysis/Electro-Discharge Technology for MMCs

Materials ◽

10.3390/ma15020617 ◽

2022 ◽

Vol 15 (2) ◽

pp. 617

Author(s):

Jing Li ◽

Wanwan Chen ◽

Yongwei Zhu

Keyword(s):

Ultrasonic Vibration ◽

Orthogonal Experiment ◽

Spindle Speed ◽

Machining Efficiency ◽

Matrix Composites ◽

Two Dimensional ◽

Machining Performance ◽

Factors Affecting ◽

Electro Discharge Machining ◽

Workpiece Vibration

Ultrasonic vibration-composited electrolysis/electro-discharge machining technology (UE/DM) is effective for machining particulate-reinforced metal matrix composites (MMCs). However, the vibration of the tool or workpiece suitable for holes limits the application of UE/DM. To improve the generating machining efficiency and quality of flat and curved surfaces, in this study, we implemented two-dimensional ultrasonic vibration into UE/DM and constructed a novel method named two-dimensional ultrasonic vibration-composited electrolysis/electro-discharge machining (2UE/DM). The influence of vibration on the performance of 2UE/DM compared to other process technologies was studied, and an orthogonal experiment was designed to optimize the parameters. The results indicated that the materiel remove rate (MRR) mainly increased via voltage and tool vibration. The change current was responsible for the MRR in the process. Spindle speed and workpiece vibration were not dominant factors affecting the MRR; the spindle speed and tool and workpiece vibration, which reduced the height difference between a ridge and crater caused by abrasive grinding, were responsible for surface roughness (Ra) and form precision (δ). Additionally, the optimized parameters of 1000 rpm, 3 V, and 5 um were conducted on MMCs of 40 SiCp/Al and achieved the maximum MRR and minimum Ra and δ of 0.76 mm3/min, 3.35 um, and 5.84%, respectively. This study’s findings provide valuable process parameters for improving machining efficiency and quality for MMCs of 2UE/DM.

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Powder-mixed electro-discharge machining performance of Inconel 718: effect of concentration of multi-walled carbon nanotube added to the dielectric media

Sadhana ◽

10.1007/s12046-020-01378-2 ◽

2020 ◽

Vol 45 (1) ◽

Cited By ~ 2

Author(s):

Thrinadh Jadam ◽

Santosh Kumar Sahu ◽

Saurav Datta ◽

Manoj Masanta

Keyword(s):

Carbon Nanotube ◽

Inconel 718 ◽

Machining Performance ◽

Electro Discharge Machining ◽

Dielectric Media ◽

Multi Walled Carbon Nanotube

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Performance comparison of coated carbide tool under different cooling/lubrication environments during face milling of Inconel-625 and Stainless Steel 304

World Journal of Engineering ◽

10.1108/wje-06-2018-0194 ◽

2019 ◽

Vol 16 (2) ◽

pp. 287-295 ◽

Cited By ~ 1

Author(s):

Pragat Singh ◽

J.S. Dureja ◽

Harwinder Singh ◽

Manpreet S. Bhatti

Keyword(s):

Tool Wear ◽

Wear Behavior ◽

Face Milling ◽

Cutting Fluid ◽

Inconel 625 ◽

Machining Performance ◽

Content Type ◽

Stainless Steel 304 ◽

Coated Carbide ◽

Ss 304

PurposeThis study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys).Design/methodology/approachMachining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy.FindingsThe results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life.Research limitations/implicationsInconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions.Originality/valueThe literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly machining.

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