Machinability Studies in Drilling of Inconel 718 Super Alloy

2015 ◽  
Vol 787 ◽  
pp. 480-484
Author(s):  
M. Vimalesh ◽  
Srikanth Prabhu ◽  
K.S. Vijay Sekar
Keyword(s):  
Cross Sections ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Machining Process ◽  
Limiting Factor ◽  
The Impact ◽  
Thrust Forces ◽  
Cutting Speeds

Inconel 718, a Nickel based superalloy is widely used for aerospace applications mainly due to its high temperature resistance and high strength to weight ratio. Its poor machinability is a limiting factor in commercial, cost intensive applications. This paper investigates the machinability of Inconel 718 in high speed drilling. The impact of the material on thrust forces, torque and chip microstructure have been measured at four different cutting speeds – 19, 27,43 and 67 m/min. The high tensile strength coupled with low thermal conductivity compounds the machining process. The thrust forces decrease with cutting speed, but the torque fluctuates at intermediate cutting speeds. Chip formation is continuous across cutting speeds, with thin cross sections and evidence of saw tooth edges. Inconel work hardens more than titanium alloys and shows good ductile to brittle transition at low temperatures creating chips of lesser length as observed using scanning electron microscopy.

scholarly journals Impact of Cutting Forces and Chip Microstructure in High Speed Machining of Carbon Fiber – Epoxy Composite Tube

2017 ◽  
Vol 62 (3) ◽  
pp. 1771-1777 ◽  
Author(s):  
Y. Allwin Roy ◽  
K. Gobivel ◽  
K.S. Vijay Sekar ◽  
S. Suresh Kumar
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Cutting Parameters ◽  
High Speed Machining ◽  
The Impact ◽  
Thrust Forces

AbstractCarbon fiber reinforced polymeric (CFRP) composite materials are widely used in aerospace, automobile and biomedical industries due to their high strength to weight ratio, corrosion resistance and durability. High speed machining (HSM) of CFRP material is needed to study the impact of cutting parameters on cutting forces and chip microstructure which offer vital inputs to the machinability and deformation characteristics of the material. In this work, the orthogonal machining of CFRP was conducted by varying the cutting parameters such as cutting speed and feed rate at high cutting speed/feed rate ranges up to 346 m/min/ 0.446 mm/rev. The impact of the cutting parameters on cutting forces (principal cutting, feed and thrust forces) and chip microstructure were analyzed. A significant impact on thrust forces and chip segmentation pattern was seen at higher feed rates and low cutting speeds.

scholarly journals Deformation Structures and Tool Wear during High-Speed Machining

2013 ◽  
Vol 10 (1) ◽  
pp. 12-17
Author(s):  
Karol Vasilko
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Tool Material ◽  
Machining Process ◽  
Surface Dynamics ◽  
Machined Surface ◽  
Deformation Structures ◽  
Cutting Speeds ◽  
Tool Durability

Abstract Tendencies towards increasing cutting speeds during machining can be observed recently. The first wave of increasing cutting speeds occured in the 60s of the previous century. However, suitable tool material was not available at that time. Increasing cutting speed is possible only following the development of cutting material, resistant against high temperatures, abrasive, adhesive and diffusive wear. It is obvious that the process of chip creation, quality of machined surface, dynamics of machining process and temperature of cutting change considerably with cutting speed. To be able to apply higher cutting speeds in production machining, it is necessary to know the dependence of those characteristics on cutting speed. Some of those phenomena, which are linked with cutting speed, will be explained in the paper. Key words: machining, cutting speed, tool durability, surface quality

The Research on Milling Force in High-Speed Milling Nickel-Based Superalloy of Inconel 718

2013 ◽  
Vol 395-396 ◽  
pp. 1031-1034
Author(s):  
Can Zhao ◽  
Yu Bo Liu
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Depth ◽  
Milling Force ◽  
High Speed Milling ◽  
Nickel Based Superalloy ◽  
Cutting Speeds

This paper makes an experiment in high-speed milling of Inconel 718. Cutting tests were performed using round and ceramic tools, at feeds from 0.06 to 0.14 mm/tooth, Axial Depth of Cut from0.5 to 1.5mm,and cutting speeds ranging from 500 to 1037 m/min. The behaviour of the cutting forces during machining was then measure. The results show that cutting force increases first and then decreases with the increase of feed per tooth, the tool chipping and groove wear were found with the increase of axial cutting depth, and cutting force is increased; the increase in cutting force with the cutting speed increases, when the cutting speed reaches a critical speed, the cutting force as the cutting speed increases began to decline.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Experimental Studies on Cutting Temperature of Nickel-Based Supper Alloy Inconel 718

2013 ◽  
Vol 584 ◽  
pp. 20-23
Author(s):  
Mao Hua Xiao ◽  
Ning He ◽  
Liang Li ◽  
Xiu Qing Fu
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Experimental Studies ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
The Impact

The method to measure the cutting speed when high speed milling nickel alloy Inconel 718 based on semi-artificial thermocouple. The cutting parameters, tool wear and so on the cutting temperature were analyzed. The tests showed that the temperature was gradually increased with the increase of cutting speed. The cutting speed must be more than 600m/min, when the ceramic tools would perform better cutting performance in the high-speed milling nickel-based superalloy. In order to achieve more efficient machining, milling speed can be increased to more than 1000m/min. The impact amount of Radial depth of cut and feed per tooth were relatively small.

Machinability Improvement by Workpiece Preheating during End Milling AISI H13 Hardened Steel

2011 ◽  
Vol 264-265 ◽  
pp. 888-893
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

Effect of Cutting Speed on Surface Integrity in High Speed Machining Nickel-Based Superalloy Inconel 718

2011 ◽  
Vol 697-698 ◽  
pp. 208-212
Author(s):  
Zhan Qiang Liu ◽  
Cheng Ming Cao ◽  
J. Du ◽  
Zhen Yu Shi
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Cnc Machining ◽  
Machined Surface ◽  
Surface Residual Stresses ◽  
Machined Surface Integrity ◽  
Cutting Speeds

Surface integrity is becoming important to satisfy the increasing requirements service life of machined parts. The purpose of this study is to investigate the effects of cutting speeds on surface integrity of Inconel 718. Experiments are conducted on a CNC machining center under various cutting speeds. The machined surface integrity is evaluated in terms of surface roughness, microhardness and residual stress. Experimental results show that machined surface integrity of Inconel 718 is sensitivity to the variations of cutting speeds. The surface roughness firstly increases with the cutting speeds increasing at the range from 50 m/min to 200 m/min, then decreases with the further increasing of the cutting speeds. For microhardness, it can be seen that work-hardening for the machined surface is serious. The surface residual stresses are tensile ones at the range of the selected cutting speeds from 50 m/min to 3,000 m/min in this research.

Brittle Removal Mechanism of Ductile Materials With Ultrahigh-Speed Machining

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
Bing Wang ◽  
Zhanqiang Liu ◽  
Guosheng Su ◽  
Xing Ai
Keyword(s):  
Aluminum Alloy ◽  
Material Property ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Machining Process ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Removal Mechanism ◽  
Ductile Materials

Material removal mechanism depends on the material property and machining parameters during machining process. This paper investigates the brittle removal mechanism of ductile materials with ultrahigh-speed machining. Based on the theory of stress wave propagation, the prediction model of critical cutting speed for ultrahigh-speed machining is proposed. The predicted critical cutting speed values are then validated with ultrahigh-speed machining experiments of Inconel 718 and 7050-T7451 aluminum alloy at the cutting speeds range from 50 m/min to 8000 m/min. The experimental results show that fragmented chips are produced above the critical cutting speed of 7000 m/min for Inconel 718 and 5000 m/min for 7050-T7451 aluminum alloy. The scanning electron microscopy (SEM) micrographs of fragmented chip fracture surface and finished workpiece surface are analyzed. Large amounts of cleavage steps and brittle cracks are observed on the fragmented chip surface. With the brittle cracks remains, the finished surface quality of ultrahigh-speed machining is worse than that of high-speed machining. The results show that the material property undergoes ductile-to-brittle transition so the brittle regime machining of ductile materials can be implemented with ultrahigh-speed machining. Taking both the machining efficiency and machining quality into account, the ultrahigh-speed machining is recommended to apply in rough machining or semifinishing, while high-speed machining is recommended to apply in finishing process. In the end, the definition and essence of ultrahigh-speed machining are concluded. This paper is enticing from both the engineering and the analytical perspectives aimed at revealing the mechanism of ultrahigh-speed machining and optimizing the machining parameters.

scholarly journals Thermographic Study of Chip Temperature in High-Speed Dry Milling Magnesium Alloys

2016 ◽  
Vol 7 (2) ◽  
pp. 86-92 ◽  
Author(s):  
Józef Kuczmaszewski ◽  
Ireneusz Zagórski ◽  
Piotr Zgórniak
Keyword(s):  
Temperature Measurement ◽  
Magnesium Alloys ◽  
High Speed ◽  
Machining Process ◽  
Dry Milling ◽  
Technological Parameters ◽  
Chip Temperature ◽  
Thermographic Study ◽  
On Chip ◽  
The Impact

Abstract This paper presents an overview of the state of knowledge on temperature measurement in the cutting area during magnesium alloy milling. Additionally, results of own research on chip temperature measurement during dry milling of magnesium alloys are included. Tested magnesium alloys are frequently used for manufacturing elements applied in the aerospace industry. The impact of technological parameters on the maximum chip temperature during milling is also analysed. This study is relevant due to the risk of chip ignition during the machining process.

Numerical Simulation of Cutting Force in High Speed Machining of Inconel 718

2020 ◽  
Vol 856 ◽  
pp. 43-49
Author(s):  
Santosh Kumar Tamang ◽  
Nabam Teyi ◽  
Rinchin Tashi Tsumkhapa
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Experimental Result ◽  
Work Piece ◽  
High Speed Machining ◽  
Numerical Result ◽  
3D Software

Machining is one of the major manufacturing processes that converts a raw work piece of arbitrary size into a finished product of definite shape of predetermined size by suitably controlling the relative motion between the tool and the work. Lately, machining process is shifting towards high speed machining (HSM) from conventional machining to improve and efficiently increase production, and towards dry machining from excessive coolant used wet machining to improve economy of production. And the tools used are mostly hardened alloys to facilitate HSM. The work piece materials are continually improving their properties by emergence and development of newer and high resistive super alloys (HRSA). In this paper an attempt has been made to validate an experimental result of cutting force obtained by performing HSM on an HRSA Inconel 718, by comparing it with the numerical result obtained by simulating the same setting using DEFORM 3D software. Based on the comparison it is found that the simulated results exhibit close proximity with the experimental results validating the experimental results and the effectiveness of the software.

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