scholarly journals Optimization of Cutting Process Parameters in Inclined Drilling of Inconel 718 Using Finite Element Method and Taguchi Analysis

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 3995 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Abhishek Subramaniam
Keyword(s):  
Inclination Angle ◽  
Inconel 718 ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Element Formulation ◽  
Drilling Operation ◽  
Industrial Sectors ◽  
Depth Analysis ◽  
Inclination Angles

Nickel-based superalloys are famous in the demanding applications. Inconel 718 is one of the most commonly used nickel-based superalloys due to its extraordinary inherent properties. Inconel 718 is a suitable material for high temperature applications due to the properties such as anti-oxidization, high hot hardness, high creep, and fatigue strength. Drilling operation is one of the most widely used manufacturing operations in almost all industrial sectors. However, drilling operation is very complex in nature due to the presence of intricate geometry of the drill bit. In conventional drilling, cutting is performed by the combined action of the chisel edge and the two or more cutting lips. In depth analysis of the cutting process shows that chisel edge starts with an indentation at the center of the twist drill. Then away from the center, chisel edge performs orthogonal cutting with negative rake angle. Whereas, cutting action at the cutting lip is oblique in nature, and force analysis involves the use of element formulation due to involvement of radius. It is rarely found in the literature where drilling operation at different inclination angles is conducted and analyzed. The presented study numerically investigates the cutting performance of drilling operation, when operated at different inclination angles. The study revealed cutting force variation at different inclination angles due to the different tool workpiece engagement for each inclination. The magnitude of thrust force increased when inclination angle is changed from 30° to 60°. It can be linked with the higher chip load initially in this case as compared to the 30° inclination angle. The cutting temperature was affected by spindle speed (53.7%), followed by feed rate (33.31%) and inclination angle (3.44%).

The Simulation Analysis of Friction Effect on Cutting Process

2011 ◽  
Vol 314-316 ◽  
pp. 1065-1068
Author(s):  
Shu Jun Li ◽  
Xiao Hang Wan ◽  
Zhao Wei Dong ◽  
Yuan Yuan
Keyword(s):  
Friction Coefficient ◽  
Coulomb Friction ◽  
Simulation Analysis ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Fem Analysis ◽  
Cutting Process ◽  
Machined Surface ◽  
System Description ◽  
Cutting Model

Adopted the Lagrange quality point coordinate system description method used the FEM analysis software, the reasonable two-dimension heat-mechanic coupling orthogonal cutting model is established in this paper, which uses the ameliorated Coulomb friction theory to simulate the friction status between the chips and tools. This paper simulates the cutting process with different friction coefficient. It can draw conclusions that the cutting forces and the residual stresses of machined surface are increasing with the raising of touching length of rake face and chip, the raising of cutting temperature. The friction coefficient has the important effect on the machining quality.

A FEM and Experimental Study of Chip Formation in Orthogonal Cutting of Superalloy GH80A

2009 ◽  
Vol 626-627 ◽  
pp. 663-668
Author(s):  
Jun Li Li ◽  
Ming Chen ◽  
Bin Rong
Keyword(s):  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Rake Angle ◽  
Cutting Process ◽  
High Yield ◽  
Isotropic Model ◽  
On Chip ◽  
As Stress

The nickel-based superalloy GH80A has been widely used in kinds of aeronautical key structures because of its high yield stress and anti-fatigue performance at high temperature. However, it is also a typical difficult-to-cut material. In order to improve cutting process, kinds of methods have been applied to study cutting process including experimental approach and finite element method (FEM). In this paper, a comparison of chip formation is carried out between traditional Johnson-Cook (JC) model and Isotropic model. Besides, effects of tool rake angle and friction coefficient on chip formation are investigated by Isotropic model. FEM predicated results such as stress and cutting temperature are also analyzed. Relative turning tests are performed and comparison of chip morphology between FEM and experiment is carried out.

Effect of Tool Flank Wear on the Orthogonal Cutting Process

2007 ◽  
Vol 329 ◽  
pp. 705-710 ◽  
Author(s):  
X.L. Zhao ◽  
Yong Tang ◽  
Wen Jun Deng ◽  
F.Y. Zhang
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Element Model ◽  
Cutting Process ◽  
Temperature Fields ◽  
Tool Flank Wear ◽  
Chip Separation

A coupled thermoelastic-plastic plane-strain finite element model is developed to study orthogonal cutting process with and without flank wear. The cutting process is simulated from the initial to the steady-state of cutting force and cutting temperature, by incrementally advancing the cutting tool forward. Automatic continuous remeshing is employed to achieve chip separation at the tool tip regime. The effect of the degree of the flank wear on the cutting forces and temperature fields is analyzed. With the flank wear increasing, the maximum cutting temperature values on the workpiece and cutting tool increase rapidly and the distribution of temperature changes greatly. The increase of tool flank wear produced slight increase in cutting forces but significant increase in thrust forces.

Experimental Research on Orthogonal Cutting and Oblique Cutting of Hardened Steel GCr15

2008 ◽  
Vol 375-376 ◽  
pp. 192-196 ◽  
Author(s):  
Yu Wang ◽  
Peng Wang ◽  
Hong Min Pen ◽  
Yu Fu Li ◽  
Xian Li Liu
Keyword(s):  
Inclination Angle ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Shear Zones ◽  
Feed Speed ◽  
Oblique Cutting ◽  
Strain And Strain Rate

Experiment of hard cutting GCr15 with PCBN cutting tools, the influence of tool’s inclination angle and cutting parameters (cutting speed and feed speed) on cutting forces and cutting temperature are studied. A three-dimensional finite elements model using the commercial software Deform 3D 5.03 is developed. The friction between the tool and the chip is assumed to follow a modified Coulomb friction law and the adaptive remeshing technique is using for the formation of chip. The workpiece material property is a function of temperature, strain, and strain rate in the primary and secondary shear zones. Finite element method is used to simulate three-dimensional precision cutting, including orthogonal cutting and oblique cutting. The cutting forces and back forces are slightly changed by tool’s inclination angle. However, in high cutting speed, the cutting force decrease as the tool’s inclination angle increase, while the cutting temperature increase as the tool’s inclination angle increase. The simulation results are compared with experimentally measured data and found to be in good agreement to some extent.

scholarly journals Cutting Zone Temperature Identification During Machining of Nickel Alloy Inconel 718

2017 ◽  
Vol 14 (2) ◽  
pp. 24-29
Author(s):  
Andrej Czán ◽  
Igor Daniš ◽  
Jozef Holubják ◽  
Lucia Zaušková ◽  
Tatiana Czánová ◽  
...  
Keyword(s):  
Temperature Gradient ◽  
Inconel 718 ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Cutting Process ◽  
Maximum Temperature ◽  
Machining Processes ◽  
Machined Surface ◽  
Cutting Zone

Abstract Quality of machined surface is affected by quality of cutting process. There are many parameters, which influence on the quality of the cutting process. The cutting temperature is one of most important parameters that influence the tool life and the quality of machined surfaces. Its identification and determination is key objective in specialized machining processes such as dry machining of hard-to-machine materials. It is well known that maximum temperature is obtained in the tool rake face at the vicinity of the cutting edge. A moderate level of cutting edge temperature and a low thermal shock reduce the tool wear phenomena, and a low temperature gradient in the machined sublayer reduces the risk of high tensile residual stresses. The thermocouple method was used to measure the temperature directly in the cutting zone. An original thermocouple was specially developed for measuring of temperature in the cutting zone, surface and subsurface layers of machined surface. This paper deals with identification of temperature and temperature gradient during dry peripheral milling of Inconel 718. The measurements were used to identification the temperature gradients and to reconstruct the thermal distribution in cutting zone with various cutting conditions.

scholarly journals Predicting Cutting Force and Primary Shear Behavior in Micro-Textured Tools Assisted Machining of AISI 630: Numerical Modeling and Taguchi Analysis

Micromachines ◽  
2022 ◽  
Vol 13 (1) ◽  
pp. 91
Author(s):  
Shafahat Ali ◽  
Said Abdallah ◽  
Salman Pervaiz
Keyword(s):  
Tool Life ◽  
High Performance ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Cutting Fluids ◽  
Machining Performance

The cutting tool heats up during the cutting of high-performance super alloys and it negatively affects the life of the cutting tool. Improved tool life can enhance both the machinability and sustainability of the cutting process. To improve the tool life preferably cutting fluids are utilized. However, the majority of cutting fluids are non-biodegradable in nature and pose harmful threats to the environment. It has been established in the metal cutting literature that introducing microgrooves at the cutting tool rake face can significantly reduce the coefficient of friction (COF). Reduction in the COF promotes anti-adhesive behavior that improves the tool life. The current study numerically investigates the orthogonal cutting process of AISI 630 Stainless Steel using different micro grooved cutting tools. Results of the numerical simulations point to the positive influence of micro grooves on tool life. The results of the main effects found that the cutting temperature was decreased by approximately 10% and 7% with rectangular and triangular micro grooved tools, respectively. Over machining performance indicated that rectangular micro groove tools provided comparatively better performance.

Study on Temperature Effect in Micro-Cutting Process

2011 ◽  
Vol 268-270 ◽  
pp. 2077-2080
Author(s):  
Zi Yang Cao ◽  
Hua Li
Keyword(s):  
Temperature Effect ◽  
Orthogonal Cutting ◽  
Temperature Drop ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Process ◽  
Material Strength ◽  
Uncut Chip Thickness ◽  
Micro Cutting

A coupled thermo-mechanical model is used to simulate two-dimensional orthogonal cutting process based on simulation model of micro-cutting. The temperature effect in micro-cutting process is studied deeply through FEM combined with micro-cutting experiments. The results indicate that cutting temperature decreases at the tool-chip interface with reduction in uncut chip thickness at high cutting speed and large uncut chip thickness. The temperature drop tends to have a hardening effect on the material strength, which in turn causes an increase in the specific cutting energy.

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