scholarly journals Optimization of Atomized Spray Cutting Fluid Eco-Friendly Turning of Inconel 718 Alloy Using ARAS and CODAS Methods

2021 ◽  
Author(s):  
Vinothkumar Sivalingam ◽  
Ganeshkumar Poogavanam ◽  
Yuvaraj Natarajan ◽  
Jie Sun
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Tool Life ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Parameter Setting ◽  
Inconel 718 Alloy ◽  
Desirability Index

Abstract Atomized spray cutting fluid (ASCF) is a sophisticated machining technique that achieves higher productivity, enhanced surface quality, extended tool life, and cost benefits. This research aims to analyze the influence of cutting process parameters on Inconel 718 alloy turning in dry and ASCF cutting environments. The critical machining indices such as surface roughness, machining cost, power consumption, and tool life were analyzed concerning these two cooling environments. The cutting parameters were optimized using desirability functional analysis and two types of multicriteria decision making (MCDM) method, such as additive ratio assessment method (ARAS) and combinative distance-based assessment (CODAS) method, were investigated. The composite desirability index (CD) of optimum parameter setting(A2B1C2D2) is improved by 6.34 % compared to the initial parameter setting (A2B1C2D1). The optimum parameters from the MCDM technique are obtained as a cutting speed of 200 m/min, feed rate of 0.08 mm/rev, and depth of cut of 0.2 mm under ASCF environment. ASCF machining significantly minimize the surface roughness, machining cost and power consumption, maximize the tool life by about 16%, 51%, 17% and 48% respectively as compared with dry machining

Technological Investigation of Effect of Machining Parameter on Tool Life

2020 ◽  
Vol 22 (4) ◽  
pp. 41-53
Author(s):  
Manojkumar Sheladiya ◽  
◽  
Shailee Acharya ◽  
Ghanshyam Acharya ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Numerical Control ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Time ◽  
Machining Parameter

Introduction. The machinability is typical criteria to be investigated and different authors suggested different parameters describing its quantification. Different parameters i. e. speed, feed, depth of cut, tool work-piece combination, machine types and its condition, cutting fluid, machinist expertise, etc. are contributing directly to the tool life. The selection of the tool for the machining impacts greatly on the economic viability of the machining in terms of energy usage and tooling costs. The method of investigation. The current research emphasis mainly on tool life investigation when machining the mild steel specimens ISRO 50, BIS 1732:1989 at constant cutting speed i.e. 200 m / min. In the industries the mild steel material is commonly used for various products manufacturing. Considering the high demands on productivity and surface finish, machining at 200 m / min is the preferred. The computerized numerical control machine (CNC DX-150) is used for the turning. The four corner insert (TNMG 120408) is used for different machining times i.e. 10, 15, 20 and 25 minutes respectively. The flank wear of the tool is measured with calibrated optical microscope. The temperature of the tool corner during machining is continuously measured for possible impact of temperature on bonding properties of the tool insert and impact on red hardness. Results and discussion. The plot of flank wear vs. machining time will give the value of tool life. The other quality output parameter, such as surface roughness, is measured after machining, indicating surface irregularities in root means square value. Efforts have been made to identify the relationship of tool life, machining time, the quantity of metal removed, surface roughness, and tool bit temperature.

Machining parameters effect in dry turning of AISI 316L stainless steel using coated carbide tools

2015 ◽  
Vol 231 (4) ◽  
pp. 676-683 ◽  
Author(s):  
Rusdi Nur ◽  
MY Noordin ◽  
S Izman ◽  
D Kurniawan
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Power Consumption ◽  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Machining Parameters ◽  
Aisi 316L ◽  
Coated Carbide

Austenitic stainless steel AISI 316L is used in many applications, including chemical industry, nuclear power plants, and medical devices, because of its high mechanical properties and corrosion resistance. Machinability study on the stainless steel is of interest. Toward sustainable manufacturing, this study also includes the power consumption during machining along with other machining responses of cutting force, surface roughness, and tool life. Turning on the stainless steel was performed using coated carbide tool without using cutting fluid. The turning was performed at various cutting speeds (90, 150, and 210 m/min) and feeds (0.10, 0.16, and 0.22 mm/rev). Response surface methodology was adopted in designing the experiments to quantify the effect of cutting speed and feed on the machining responses. It was found that cutting speed was proportional to power consumption and was inversely proportional to tool life, and showed no significant effect on the cutting force and the surface roughness. Feed was proportional to cutting force, power consumption, and surface roughness and was inversely proportional to tool life. Empirical equations developed from the results for all machining responses were shown to be useful in determining the optimum cutting parameters range.

Multi-Criteria Optimization in End Milling of AISI D2 Hardened Steel Using Coated Carbide Inserts

2011 ◽  
Vol 264-265 ◽  
pp. 907-912
Author(s):  
A.N. Mustafizul Karim ◽  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Machining Operations ◽  
Coated Carbide ◽  
Desirability Index

This paper proposes a multi-criteria optimization technique using the mathematical models developed by the response surface methodology (RSM) for the target responses combined with desirability indices for the determining the optimum cutting parameters in end milling of AISI D2 hardened steels. Different responses may require different targets either being maximized or minimized. Simultaneous achievement of the optimized (maximum or minimum) values of all the responses is very unlikely. In machining operations tool life and volume metal removed are targeted to be maximized whereas the machined surface roughness need to be at minimum level. Models showing the combined effect of the three control factors such as cutting speed, feed, and depth of cut are developed. However, a particular combination of parameter levels appears to be optimum for a particular response but not for all. Thus adoption of the method of consecutive searches with higher desirability values is found to be appropriate. In this study the desirability index reaches to a maximum value of 0.889 after five consecutive solution searching. At this stage, the optimum values of machining parameters - cutting speed, depth of cut and feed were determined as 44.27 m/min, 0.61 mm, 0.065 mm/tooth respectively. Under this set condition of machining operations a surface roughness of 0.348 μm and volume material removal of 7.45 cm3 were the best results compared to the rest four set conditions. However, the tool life would be required to compromise slightly from the optimum value.

OPTIMIZATION OF PROCESS PARAMETERS AFFECTING CUTTING FORCE, POWER CONSUMPTION AND SURFACE ROUGHNESS USING TAGUCHI-BASED GRAY RELATIONAL ANALYSIS IN TURNING AISI 1040 STEEL

2021 ◽  
Author(s):  
MAHIR AKGÜN
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Cutting Force ◽  
Cutting Speed ◽  
System Optimization ◽  
Gray Relational Analysis ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Significance Level ◽  
Relational Analysis

This study focuses on optimization of cutting conditions and modeling of cutting force ([Formula: see text]), power consumption ([Formula: see text]), and surface roughness ([Formula: see text]) in machining AISI 1040 steel using cutting tools with 0.4[Formula: see text]mm and 0.8[Formula: see text]mm nose radius. The turning experiments have been performed in CNC turning machining at three different cutting speeds [Formula: see text] (150, 210 and 270[Formula: see text]m/min), three different feed rates [Formula: see text] (0.12 0.18 and 0.24[Formula: see text]mm/rev), and constant depth of cut (1[Formula: see text]mm) according to Taguchi L18 orthogonal array. Kistler 9257A type dynamometer and equipment’s have been used in measuring the main cutting force ([Formula: see text]) in turning experiments. Taguchi-based gray relational analysis (GRA) was also applied to simultaneously optimize the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]). Moreover, analysis of variance (ANOVA) has been performed to determine the effect levels of the turning parameters on [Formula: see text], [Formula: see text] and [Formula: see text]. Then, the mathematical models for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) have been developed using linear and quadratic regression models. The analysis results indicate that the feed rate is the most important factor affecting [Formula: see text] and [Formula: see text], whereas the cutting speed is the most important factor affecting [Formula: see text]. Moreover, the validation tests indicate that the system optimization for the output parameters ([Formula: see text], [Formula: see text] and [Formula: see text]) is successfully completed with the Taguchi method at a significance level of 95%.

Tool Life Analysis when Turning Ti-6Al-4V Using Vegetable Oil-Based Cutting Fluid

2017 ◽  
Vol 882 ◽  
pp. 36-40
Author(s):  
Salah Gariani ◽  
Islam Shyha ◽  
Connor Jackson ◽  
Fawad Inam
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Vegetable Oil ◽  
Flank Wear ◽  
Cutting Speed ◽  
Fractional Factorial ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Fluid Concentration

This paper details experimental results when turning Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. The effects of coolant concentration and working conditions on tool flank wear and tool life were evaluated. L27 fractional factorial Taguchi array was employed. Tool wear (VBB) ranged between 28.8 and 110 µm. The study concluded that a combination of VOs based cutting fluid concentration (10%), low cutting speed (58 m/min), feed rate (0.1mm/rev) and depth of cut (0.75mm) is necessary to minimise VBB. Additionally, it is noted that tool wear was significantly affected by cutting speeds. ANOVA results showed that the cutting fluid concentration is statistically insignificant on tool flank wear. A notable increase in tool life (TL) was recorded when a lower cutting speed was used.

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.

scholarly journals Optimization of Power Consumption Associated with Surface Roughness in Ultrasonic Assisted Turning of Nimonic-90 Using Hybrid Particle Swarm-Simplex Method

Materials ◽  
2019 ◽  
Vol 12 (20) ◽  
pp. 3418 ◽  
Author(s):  
Khanna ◽  
Airao ◽  
Gupta ◽  
Song ◽  
Liu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Fitness Function ◽  
Particle Swarm ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Hybrid Particle ◽  
Ultrasonic Assisted

These days, power consumption and energy related issues are very hot topics of research especially for machine tooling process industries because of the strict environmental regulations and policies. Hence, the present paper discusses the application of such an advanced machining process i.e., ultrasonic assisted turning (UAT) process with the collaboration of nature inspired algorithms to determine the ideal solution. The cutting speed, feed rate, depth of cut and frequency of cutting tool were considered as input variables and the machining performance of Nimonic-90 alloy in terms of surface roughness and power consumption has been investigated. Then, the experimentation was conducted as per the Taguchi L9 orthogonal array and the mono as well as bi-objective optimizations were performed with standard particle swarm and hybrid particle swarm with simplex methods (PSO-SM). Further, the statistical analysis was performed with well-known analysis of variance (ANOVA) test. After that, the regression equation along with selected boundary conditions was used for creation of fitness function in the subjected algorithms. The results showed that the UAT process was more preferable for the Nimconic-90 alloy as compared with conventional turning process. In addition, the hybrid PSO-SM gave the best results for obtaining the minimized values of selected responses.

Effect of machining parameters on the surface finish of a metal matrix composite under dry cutting conditions

2015 ◽  
Vol 231 (6) ◽  
pp. 913-923 ◽  
Author(s):  
Brian Boswell ◽  
Mohammad Nazrul Islam ◽  
Ian J Davies ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Dry Cutting

The machining of aerospace materials, such as metal matrix composites, introduces an additional challenge compared with traditional machining operations because of the presence of a reinforcement phase (e.g. ceramic particles or whiskers). This reinforcement phase decreases the thermal conductivity of the workpiece, thus, increasing the tool interface temperature and, consequently, reducing the tool life. Determining the optimum machining parameters is vital to maximising tool life and producing parts with the desired quality. By measuring the surface finish, the authors investigated the influence that the three major cutting parameters (cutting speed (50–150 m/min), feed rate (0.10–0.30 mm/rev) and depth of cut (1.0–2.0 mm)) have on tool life. End milling of a boron carbide particle-reinforced aluminium alloy was conducted under dry cutting conditions. The main result showed that contrary to the expectations for traditional machined alloys, the surface finish of the metal matrix composite examined in this work generally improved with increasing feed rate. The resulting surface roughness (arithmetic average) varied between 1.15 and 5.64 μm, with the minimum surface roughness achieved with the machining conditions of a cutting speed of 100 m/min, feed rate of 0.30 mm/rev and depth of cut of 1.0 mm. Another important result was the presence of surface microcracks in all specimens examined by electron microscopy irrespective of the machining condition or surface roughness.

scholarly journals OPTIMUM PERFORMANCE OF GREEN MACHINING ON THIN WALLED TI6AL4V USING RSM AND ANN IN TERMS OF CUTTING FORCE AND SURFACE ROUGHNESS

2019 ◽  
Vol 81 (6) ◽  
Author(s):  
Muhammad Yanis ◽  
Amrifan Saladin Mohruni ◽  
Safian Sharif ◽  
Irsyadi Yani
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Ann Model ◽  
Green Machining ◽  
Radial Depth ◽  
Thin Walled

Thin walled titanium alloys are mostly applied in the aerospace industry owing to their favorable characteristic such as high strength-to-weight ratio. Besides vibration, the friction at the cutting zone in milling of thin-walled Ti6Al4V will create inconsistencies in the cutting force and increase the surface roughness. Previous researchers reported the use of vegetable oils in machining metal as an effort towards green machining in reducing the undesirable cutting friction. Machining experiments were conducted under Minimum Quantity Lubrication (MQL) using coconut oil as cutting fluid, which has better oxidative stability than other vegetable oil. Uncoated carbide tools were used in this milling experiment. The influence of cutting speed, feed and depth of cut on cutting force and surface roughness were modeled using response surface methodology (RSM) and artificial neural network (ANN). Experimental machining results indicated that ANN model prediction was more accurate compared to the RSM model. The maximum cutting force and surface roughness values recorded are 14.89 N, and 0.161 µm under machining conditions of 125 m/min cutting speed, 0.04 mm/tooth feed, 0.25 mm radial depth of cut (DOC) and 5 mm axial DOC. 

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.

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