Surface Integrity when Drilling Nickel-Based Superalloy under MQL Supply

2010 ◽  
Vol 443 ◽  
pp. 365-370 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Hiroyuki Sasahara
Keyword(s):  
Surface Roughness ◽  
Palm Oil ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Surface Defects ◽  
Surface Deformation ◽  
Aerospace Industry ◽  
Synthetic Ester ◽  
Nickel Based Superalloy ◽  
Functional Behavior

The components being manufactured in aerospace industry must be capable of being utilized for long periods without failure. Thus, the functional behavior of these machined components is greatly dependent upon their surface integrity. The present work compares the performance of palm oil and synthetic ester on surface integrity when drilling of Inconel 718. The results indicate the substantial benefit of MQL by palm oil on microhardness, surface roughness, surface defects and sub-surface deformation.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

Surface Integrity Studies in Ball End Milling of Thin Shaped Cantilever Inconel 718

2014 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Raju S. Pawade
Keyword(s):  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
Surface Defects ◽  
End Milling ◽  
Surface Region ◽  
Lower Surface ◽  
Machined Surface ◽  
Ball End Milling ◽  
Integrity Analysis

The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever plate of Inconel 718. It is noticed that the workpiece deflection has significantly contributed to machined surface integrity in terms of surface topography and subsurface microhardness. The ball end milling performed with 15° workpiece inclination with horizontal tool path produced higher surface integrity which varies with the location of machined surface region. In general, the mid portion of the machined plate shows lower surface roughness and microhardness with less surface defects.

Effect of Machining Parameters and MQL Liquids on Surface Integrity of High Speed Drilling Ti-6Al-4V

2010 ◽  
Vol 447-448 ◽  
pp. 816-820 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Hiroyuki Sasahara
Keyword(s):  
Surface Roughness ◽  
Palm Oil ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Machined Surface ◽  
Subsurface Deformation ◽  
High Speed Drilling ◽  
Coated Carbide

Surface integrity is particularly important for the aerospace industry components in order to permit longer service life and maximized its reliability. This present work compares the performance of palm oil and synthetic ester on surface roughness, surface defect, microhardness and subsurface deformation when high speed drilling of Ti-6Al-4V under MQL condition. The drilling tests were conducted with AlTiN coated carbide tool. The surface roughness decreased with increasing in cutting speed and thicker subsurface deformation was formed underneath the machined surface. Grooves, cavities, pit holes, microcracks and material smearing were the dominant surface damages thus deteriorated the machined surface. For both lubricants, the machined surface experienced from thermal softening and work hardening effect thus gave a variation in microhardness values. The results indicated the substantial benefit of MQL by palm oil on surface integrity.

INVESTIGATION OF SURFACE INTEGRITY DURING TURNING INCONEL 718

2017 ◽  
Vol 41 (3) ◽  
pp. 387-394 ◽  
Author(s):  
M. Anthony Xavior ◽  
M. Manohar ◽  
Mahesh Madhukar Patil ◽  
P. Jeyapandiarajan
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Surface Quality ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Research Work ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Minimum Residual ◽  
Major Surface

Surface roughness and residual stress are considered to be major surface integrity issues that directly affect the quality and life of the components. The current research work highlights surface quality and residual stresses induced while machining Inconel 718 with a range of cutting parameters and cutting environments. Further, the study aimed to determine the optimal parameters/conditions in terms of cutting speeds, tool materials and cutting conditions to achieve better surface quality and minimum residual stress values. Minimum quantity lubrication resulted in minimum residual values for all cutting inserts and cutting velocities. The minimum surface roughness was obtained while machining at 100 m/min using a carbide insert under flood cooling condition.

scholarly journals Effects of Tool Wear on Machined Surface Integrity During Milling of Inconel 718

2021 ◽  
Author(s):  
Liang Tan ◽  
Changfeng Yao ◽  
Dinghua Zhang ◽  
Minchao Cui ◽  
Xuehong Shen
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Machined Surface Integrity

Abstract This paper investigates the effects of tool wear on the machined surface integrity characteristics, including the surface roughness, surface topography, residual stress, microhardness and microstructure, during ball-end milling of Inconel 718. Tool wear, tool lifetime, and cutting force are measured. In addition, a two-dimensional finite element-based model is developed to investigate the cutting temperature distribution in the chip–tool–workpiece contact area. Results show that the ball nose end mill achieves tool lifetime of approximately 350 min. The cutting forces increase sharply with a greater tool flank wear width, while the highest cutting temperature has a decreasing tend at a flank wear width of 0.3 mm. Higher tool flank wear width produces larger surface roughness and deteriorative surface topography. A high-amplitude (approximately −700 MPa) and deep layer (approximately 120 mm) of compressive residual stress are induced by a worn tool with 0.3 mm flank wear width. The surface microhardness induced by new tool is larger than that induced by worn tool. Plastic deformation and strain streamlines are observed within 10 mm depth beneath the surface. The results in this paper provide an optimal tool wear criterion which integrates the surface integrity requirements and the tool lifetime for ball-end finish milling of Inconel 718.

The Influence Factors and Prediction of Curve Surface Roughness in Micro-Milling Nickel-Based Superalloy

2018 ◽  
Author(s):  
Xiaohong Lu ◽  
Xinxin Wang ◽  
Jing Sun ◽  
Hong Zhang ◽  
Yixuan Feng
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
Relative Error ◽  
Inconel 718 ◽  
Curve Surface ◽  
Influence Factors ◽  
Least Square ◽  
Micro Milling ◽  
Maximum Relative Error ◽  
Nickel Based Superalloy

Micro structure/parts during their useful life are significantly influenced by surface roughness quality. Machining of curve shapes is a necessity in micro-milling process. However, surface roughness in micro-milling curved surfaces is more complex, and few studies on the influence factors and prediction of the micro-milled curve surface roughness in micro-milling nickel-based superalloy have been done. The purpose of this paper is to study the effects of spindle speed, the radius of ball-end mill, axial cutting depth, and feed per tooth on the curved surface roughness in micro-milling Inconel 718 process based on single factor and orthogonal experiments. Utilizing the least square method, we build a surface roughness prediction model of micro-milled Inconel 718. Finally, experiments are conducted to verify the accuracy of the developed prediction model. The results indicate that the maximum relative error is 10.68%, and the mean relative error is 8.04%, which prove that the prediction model is correct. The work can provide a reference for selection of cutting parameters in micro-milling Inconel 718.

Surface Integrity in MQL Drilling Nickel-Based Superalloy

2010 ◽  
Vol 447-448 ◽  
pp. 811-815 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Hiroyuki Sasahara
Keyword(s):  
Surface Integrity ◽  
High Reliability ◽  
Cutting Speed ◽  
Machined Surface ◽  
Jet Engine ◽  
Synthetic Ester ◽  
Nickel Based Superalloy ◽  
Surface Damages ◽  
Engine Components ◽  
Coated Carbide

Nickel-based superalloys remain the most widely used of all materials in aerospace industry, contributed over 50 % of the weight of a jet engine. In machining of any jet engine components, it is necessary to satisfy the surface quality or surface integrity requirements to facilitate high reliability components. In the present study, surface integrity of Inconel 718 was studied when drilling under different lubricants. The holes were drilled individually using indexable AlTiN coated carbide drill under minimum quantity of lubricant (MQL) conditions. The results demonstrated that the machining conditions and lubricants strongly influence the surface integrity. The surface roughness decreases with the increase in cutting speed and increases with the increase in feed rate. Microhardness profiles indicated that the subsurface deformation extends up to a 100 and 150 μm for palm oil and synthetic ester, respectively underneath the machined surface. Pit holes, cavities, grooves, microcracks and surface smearing were the dominant surface damages criteria for all cases.

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