Study on the Machinability Characteristics of Superalloy K424 during High Speed Turning

2011 ◽  
Vol 188 ◽  
pp. 636-641 ◽  
Author(s):  
M.H. Xiao ◽  
N. He ◽  
L. Li ◽  
B.G. Qiu ◽  
Y. Su
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Nitrogen Gas ◽  
Ceramic Tools ◽  
High Speed Turning ◽  
Eds Analysis ◽  
Nickel Based Alloy ◽  
Notch Wear

The present paper is an attempt of an experimental investigation on the machinability of superalloy, K424 during high speed turning using different ceramic inserts under different cutting speed and cooling/lubricating condition. The effect of machining parameters on the tool wear was examined through SEM micrographs.The experimental results show that, round Al2O3＋SiCW KY4300R ceramic insert shows the best cutting performance in cutting the superalloy K424 , and it should be used in rather higher speed. Cold nitrogen gas is not recommended when machining nickel-based alloy with ceramic tools. SEM and EDS analysis shows that the ceramic tool was severely controlled by tool nose and depth-of-cut notch wear, followed by flaking and chipping.

Study of High-Speed Machining Parameters on Nickel-Based Alloy GH2132

2011 ◽  
Vol 189-193 ◽  
pp. 3142-3147 ◽  
Author(s):  
Dong Qiang Gao ◽  
Zhong Yan Li ◽  
Zhi Yun Mao
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Nickel Based Alloy

A model of stress and temperature field is established on nickel-based alloy cutting by finite element modeling and dynamic numerical simulating, and then combining high-speed machining test and orthogonality analysis method, the influence law of cutting parameters on the cutting force and tool wear has been researched, and the tool life and cutting force prediction model based on cutting parameters has been obtained. Finally, by genetic algorithm method cutting parameters are selected reasonably and optimized. The result shows that the bonding wear is main tool wear, and the influence of cutting speed on cutting force is smaller than feed per tooth and axial depth of cut.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

Taguchi Method Based Experiments of Titanium TC11 Flank Milling Parameters

2009 ◽  
Vol 407-408 ◽  
pp. 608-611 ◽  
Author(s):  
Chang Yi Liu ◽  
Cheng Long Chu ◽  
Wen Hui Zhou ◽  
Jun Jie Yi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Flank Milling ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Mill Machining

Taguchi design methodology is applied to experiments of flank mill machining parameters of titanium alloy TC11 (Ti6.5A13.5Mo2Zr0.35Si) in conventional and high speed regimes. This study includes three factors, cutting speed, feed rate and depth of cut, about two types of tools. Experimental runs are conducted using an orthogonal array of L9(33), with measurement of cutting force, cutting temperature and surface roughness. The analysis of result shows that the factors combination for good surface roughness, low cutting temperature and low resultant cutting force are high cutting speed, low feed rate and low depth of cut.

Optimization in Hot Turning of Nickel Based Alloy Using Desirability Function Analysis

2016 ◽  
Vol 24 ◽  
pp. 64-70 ◽  
Author(s):  
A.K. Parida ◽  
K.P. Maity
Keyword(s):  
Feed Rate ◽  
Function Analysis ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cutting Velocity ◽  
Nickel Based Alloy ◽  
Desirability Function Analysis ◽  
Hot Turning

This paper presents a desirability function approach in order to find out an optimal combination of Machining parameters for multi-response parameters in hot turning operation of nickel based alloy. Taguchi’s L9 orthogonal array is used for experimental design. The machining parameters such as cutting velocity, feed rate, depth of cut and temperature are optimized by multi-response considerations namely power, flank wear, and MRR. ANOVA test was carried out and it was found that cutting speed is most influence parameter followed by feed rate, depth of cut and workpiece temperature. The optimization of machining parameters was found at 5.8 m/min of cutting speed, 30 °C preheating temperature, 0.2 mm depth of cut and 0.15 mm/rev feed rate

Surface Roughness Analysis in High Speed-Dry Turning of a Tool Steel

2010 ◽  
Author(s):  
N. M. Vaxevanidis ◽  
N. I. Galanis ◽  
G. P. Petropoulos ◽  
N. Karalis ◽  
P. Vasilakakos ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Steel ◽  
High Speed ◽  
Surface Defects ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Dry Turning ◽  
Roughness Analysis

High-speed machining is widely applied for the processing of lightweight materials and also structural and tool steels. These materials are intensively used in the aerospace and the automotive industries. The advantages of high-speed machining lie not only in the speed of machining (lower costs and higher productivity) but also in attaining higher surface quality (prescribed surface roughness without surface defects). Based on this concept, in the present paper the high speed-dry turning of AISI O, (manganese-chromium-tungsten / W.-Nr. 1.2510) tool-steel specimens is reported. The influence of the main machining parameters i.e., cutting speed, feed rate and depth of cut on the resulted center-line average surface roughness (Ra) is examined. Types of wear phenomena occurred during the course of the present experimental study as well as tool wear patterns were also monitored.

The Use of the Taguchi-Grey Based to Optimize High Speed End Milling with Multiple Performance Characteristics

2006 ◽  
Vol 505-507 ◽  
pp. 835-840 ◽  
Author(s):  
Shen Jenn Hwang ◽  
Yunn Lin Hwang ◽  
B.Y. Lee
Keyword(s):  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Speed ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Performance ◽  
Grey Relational Grade ◽  
Grey Relational

This paper presents a new approach for the optimization of the high speed machining (HSM) process with multiple performance characteristics based on the orthogonal array with the grey relational analysis has been studied. Optimal machining parameters can then be determined by the grey relational grade as the performance index. In this study, the machining parameters such as cutting speed, feed rate and axial depth of cut are optimized under the multiple performance characteristics including, tool life, surface roughness, and material removal rate(MMR). As shown experimental results, machining performance in the HSM process can be improved effectively through this approach.

Using the Desirability Function as an Effective Tool in Target Costing Model

2015 ◽  
Vol 1115 ◽  
pp. 126-129
Author(s):  
Muataz Hazza F. Al Hazza ◽  
Mohamed Konneh ◽  
Mohammad Iqbal ◽  
Assem Hatem Taha ◽  
Muhammad H. Hasan
Keyword(s):  
High Speed ◽  
Desirability Function ◽  
Cutting Speed ◽  
Machining Process ◽  
304 Stainless Steel ◽  
Depth Of Cut ◽  
Target Costing ◽  
Economic Study ◽  
High Speed Turning ◽  
Coated Carbide

High speed turning (HST) is an advanced machining process that uses higher cutting speeds than those used in conventional machining. HST enables manufacturers to shorten machining times. Therefore, this approach should be followed and justified by economic study. One of the most effective tools for economic study is by developing a target-cost model to control the machining cost. The aim of this research is to develop a target costing model for high speed turning. To achieve the aim of this research, a set of experimental data was obtained in the following cutting levels: cutting speed (500-700 m/min), feed rate (1000-2000 mm/min), and depth of cut of (0.1-0.3) mm. The materials used in this research were AISI 304 stainless steel as a work piece material and coated carbide as a cutting tool. The output data was used to develop a target costing model. The desirability function has been used to optimize the model.

Optimization of Cutting Parameters using Cryogenically Treated High Speed Steel Tool by Taguchi Application

2013 ◽  
Vol 3 (1) ◽  
pp. 26-38 ◽  
Author(s):  
Lakhwinder Pal Singh ◽  
Jagtar Singh
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Cryogenic Treatment ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Small Scale ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimization Of Cutting Parameters

In the field of mechanical engineering, engineers are always looking for ways to improve the properties of materials. Cryogenic treatment of tooling steels is a proven technology to increase wear resistance and extend intervals between component replacements. The main idea of this paper is to apply Taguchi method to optimize cutting parameters in turning operation using cryogenic treated (CT) and untreated (UT) high speed steel (HSS) tools, so that the scope of cryogenic treatment on HSS tool material may be presented for the benefit of medium and small scale industry using HSS tools for cutting operation. Taguchi L25 orthogonal array is employed to study the performance characteristics in turning operations of AISI 1020 steel bars using CT and UT HSS tools. The microstructure has been found more refined and uniformly distributed after cryogenic treatment of HSS tool. It has been observed that optimum machining parameters in both the cases (CT HSS and UT HSS tools) are higher cutting speed (49.9 to 75.7 m/min.), lower feed rate (0.15 mm/rev.), medium depth of cut (0.40 mm). Analysis of variance (ANOVA) indicates that the cutting speed is most significant parameter followed by feed rate in case of CT HSS tool and depth of cut in case of UT HSS tool.

Cutting Performances of Coated PVD in High Speed End Milling of Aged Inconel 718

2013 ◽  
Vol 773-774 ◽  
pp. 653-660
Author(s):  
Mohd Shahir Kasim ◽  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
Juri Saedon ◽  
Mohd Amri Sulaiman
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Tool ◽  
Elevated Temperatures ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Notch Wear

Inconel 718 is a material exhibiting characteristic that are able to maintain strength and integrity at elevated temperatures, but it is well known as a material with poor machinability. This paper presents a study of the performance in high speed machining of TiAlN/AlCrN nanomultilayer PVD coated Inconel 718 with minimum lubrication. Investigations have been made into the effects of cutting speed, feed rate and depth of cut (DOC) on the tool life. A toolmakers microscope and a scanning electron microscope (SEM) were used to examine the tool wear and chemical attrition, respectively, on the cutting tool during machining. In the machining of aged Inconel 718, the cutting tool experienced attrition, abrasion and notch wear throughout the experiment. Notch wear was found to be the dominant failure mode during milling; this wear appeared severe when localized flank wear reached the critical zone. The influence of radial depth despite the cutting speed, well known as having the most significant effect on tool life, is also discussed.

scholarly journals Optimization of Cutting Parameters to Minimize Tooling Cost in High Speed Turning of SS304 using Coated Carbide Tool using Genetic Algorithm Method

2016 ◽  
Vol 1 (1) ◽  
pp. 11-15
Author(s):  
Muataz Hazza ◽  
Nur Amirah Najwa
Keyword(s):  
Genetic Algorithm ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Carbide Tool ◽  
High Speed Turning ◽  
Coated Carbide Tool ◽  
Optimization Of Cutting Parameters ◽  
Coated Carbide

High speed turning (HST) is an approach that can be used to increase the material removal rate (MRR) by higher cutting speed. Increasing MRR will lead to shortening time to market. In contrast, increasing the cutting speed will lead to increasing the flank wear rate and then the tooling cost.  However, the main factor that will justify the best level of cutting speed is the tooling cost which merges all in one understandable measurable factor for manufacturer. The aim of this paper is to determine experimentally the optimum cutting levels that minimize the tooling cost in machining AISI 304 as a work piece machined by a coated carbide tool using one of the non-conventional methods: Genetic Algorithm (GA). The experiments were designed using Box Behnken Design (BBD) as part of Response Surface Methodology (RSM) with three input factors: cutting speed, feeding speed and depth of cut.

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