Turning of Inconel 718 with whisker-reinforced ceramic tools applying vegetable-based cutting fluid mixed with solid lubricants by MQL

2019 ◽  
Vol 266 ◽  
pp. 530-543 ◽  
Author(s):  
Armando Marques ◽  
Mauro Paipa Suarez ◽  
Wisley Falco Sales ◽  
Álisson Rocha Machado
Keyword(s):  
Inconel 718 ◽  
Solid Lubricants ◽  
Cutting Fluid ◽  
Ceramic Tools

scholarly journals IMPROVEMENT IN MACHINING PERFORMANCE OF INCONEL 718 WITH SOLID LUBRICANTS

2018 ◽  
Vol 80 (6) ◽  
Author(s):  
Sunil Kumar ◽  
Dilbag Singh ◽  
Nirmal Singh Kalsi
Keyword(s):  
Inconel 718 ◽  
Hexagonal Boron Nitride ◽  
High Strength ◽  
Solid Lubricants ◽  
Cutting Fluid ◽  
Tool Geometry ◽  
Dry Machining ◽  
Machining Performance ◽  
Coated Carbide

From the last decade, the use of high corrosion resistance, high strength superalloys (mostly Ni- or Ti-based) at elevated temperature have significantly increased in aerospace or transport industry. Such materials are tremendously difficult to cut, develop a high temperature and deteriorate the quality of the components leading to tool wear. In place of using the cutting fluid, strict environmental limit develops new cutting methods or techniques for enhancing the tool life. This study demonstrates the performance of solid lubricants (hexagonal boron nitride and graphite) on surface quality. Tool geometry and cutting variables were selected for machining Inconel 718 with TiAlN-coated carbide inserts. The comparison has been conducted between solid lubricant assistant machining and dry machining. The studies demonstrate that the performance of solid lubricants is better than dry machining. There is 10% to 18% reduction in surface roughness with solid lubricants as compared to dry machining.

Wear behaviour of whisker-reinforced ceramic tools in the turning of Inconel 718 assisted by an atomized spray of solid lubricants

2020 ◽  
Vol 148 ◽  
pp. 106235 ◽  
Author(s):  
Vinothkumar Sivalingam ◽  
Zhuoliang Zan ◽  
Jie Sun ◽  
Baskaran Selvam ◽  
Munish Kumar Gupta ◽  
...  
Keyword(s):  
Inconel 718 ◽  
Solid Lubricants ◽  
Wear Behaviour ◽  
Ceramic Tools

Micro Textured Cutting Inserts with Solid Lubrication as Alternative Coolant to Mineral Oil-Based Cutting Fluid in Turning Operation

2021 ◽  
Vol 13 (4) ◽  
Author(s):  
C. Divya ◽  
L. Suvarna Raju ◽  
B. Singaravel
Keyword(s):  
Process Parameters ◽  
Orthogonal Array ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Solid Lubricants ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Turning Process ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

Turning process is a primary process in engineering industries and optimization of process parameters enhance the machining performance. Inconel 718 is a nickel-based superalloy, widely found applications in the manufacturing of blades, sheets and discs in aircraft engines and rocket engines. It provides toughness at low temperature, with stand high mechanical stresses at elevated temperature and creep resistance. In this work, turning process is carried out on Inconel 718 with micro whole textured cutting inserts filled with solid lubricants. Three different solid lubricants are used namely molybdenum-di-sulfide (MoS2), tungsten-di-sulfide (WS2) and calcium-di-fluoride (CaF2). Experiments are performed as per L9 orthogonal array. Statistical approaches such as orthogonal array, Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are used to find the importance and effects of machining parameters. In this study, input parameters included are feed, cutting speed and depth of cut and output parameter includes surface roughness. Optimization of process parameters is carried out and the significance is estimated. The result suggested that WS2 followed by MoS2 and CaF2 given good surface finish value. Also, solid lubricant in machining enhances the sustainability in manufacturing.

Investigations on the Application of Minimum Quantity Solid Lubrication in Turning

2017 ◽  
Author(s):  
Mayur A. Makhesana ◽  
Kaushik M. Patel
Keyword(s):  
Tool Wear ◽  
Cost Effective ◽  
Solid Lubricants ◽  
Cutting Fluid ◽  
Solid Lubrication ◽  
Machining Processes ◽  
Machined Surface ◽  
Minimum Quantity ◽  
Set Up ◽  
Experimental Findings

Machining is the manufacturing process, capable of producing required shape and size by material removal. In recent times industries are striving to enhance the performance of machining processes. One of the problem associated with machining is the amount of heat generation as a result of friction between tool and workpiece. Heat generated may affect the quality of machined surface and tool wear. In order to control it, cutting fluid is applied in large quantity. The problem arises with the use of cutting fluid is its effect on worker’s health and environment. The present investigation is an attempt to explore the use the solid lubricants in machining as an alternative to cutting fluid. The work involves development of minimum quantity solid lubrication set up. Turning experiments has been performed by applying solid lubricants mixed with cutting fluid in minimum quantity. The performance of minimum quantity solid lubrication has been assessed in form of obtained surface finish, power consumption and tool wear during turning. Experimental findings discovered the superiority of minimum quantity solid lubrication over conventional cutting fluid and can be considered as cost effective and sustainable lubrication method.

Analysis of Surface Roughness and Wear Mechanism when Cutting Hardened Steel Rolls

2018 ◽  
Vol 777 ◽  
pp. 393-396
Author(s):  
Xin Yu Song ◽  
Guo Chen Du
Keyword(s):  
Surface Roughness ◽  
Steel Industry ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Cutting Fluid ◽  
Workpiece Surface ◽  
Ceramic Tools ◽  
Low Efficiency ◽  
Almost All ◽  
Steel Rolls

In modern steel industry, hardened steel rolls are very important tools. The increase of the automobile and the mould keeps the amount of rolls increases fairly quickly. In cutting process, hardened rolls are very difficult to turn or mill, there for, almost all hardened rolls are cut only by grinding, which causes low efficiency, besides in grinding process and a lot of cutting fluid are used. In this paper, surface roughness of workpiece was analyzed of the ceramic tools in different cutting conditions. Wear machanism of crack and abrasive of cutting tools were also analyzed. The experimental and theoretical analysis confirmed that when the ceramic tools cutting cold rolls, the generation and expansion of the cracks the most important role that affect tool life and workpiece surface roughness.

Tool Wear Characteristics in Near-Dry Cutting of Ni-Based Superalloy

2015 ◽  
Vol 656-657 ◽  
pp. 404-409
Author(s):  
Shinji Yamada ◽  
Yukio Maeda ◽  
Tatsuya Wakabayashi ◽  
Kazuhide Kamiya ◽  
Hideaki Tanaka ◽  
...  
Keyword(s):  
Tool Wear ◽  
Inconel 718 ◽  
Removal Rate ◽  
Combustion Efficiency ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Cutting Stock ◽  
Jet Engines ◽  
Dry Cutting ◽  
Stock Removal

Recently, high-combustion-efficiency jet engines have become required in the aircraft industry. High burning temperatures are necessary to maximize the combustion efficiency of jet engines. Inconel 718, which has excellent mechanical and chemical properties, has been selected for use in many jet engine parts. However, Inconel 718 is a difficult material to cut because of its low thermal conductivity. Consequently, wet cutting is typically used to reduce the heat generated in cutting Inconel 718. Wet cutting, which uses a large amount of cutting fluid, is costly and requires considerable energy for maintenance and disposal of the cutting fluid, making this cutting method environmentally unfriendly. To reduce the associated cost and environmental load, the near-dry cutting method, which uses a very small amount of cutting fluid, may be preferable for cylindrical cutting of Inconel 718. However, this method has some drawbacks, such as the cutting stock removal rate and the wear on cemented carbide tools. For example, the cutting stock removal rate is lower than with wet cutting because cutting edge fracture occurs easily in near-dry cutting. In this study, we conducted experiments to examine the relationships between the tool materials, cutting speed and tool fracture in near-dry cutting and wet cutting, and we compared the results obtained using the two cutting methods. We found that an S05-type cemented carbide coating can reduce tool wear. We also found that in the early stages of cutting, between cutting speeds of V = 50 and 90 m/min, the tool wear can be comparatively reduced.

Performance of graded nano-composite ceramic tools in ultra-high-speed milling of Inconel 718

2013 ◽  
Vol 67 (9-12) ◽  
pp. 2799-2810 ◽  
Author(s):  
Guangming Zheng ◽  
Jun Zhao ◽  
Yonghui Zhou ◽  
Anhai Li ◽  
Xiaobin Cui ◽  
...  
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Composite Ceramic ◽  
Nano Composite ◽  
High Speed Milling ◽  
Ceramic Tools ◽  
Ultra High Speed

scholarly journals Progressing towards Sustainable Machining of Steels: A Detailed Review

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5162
Author(s):  
Kashif Ishfaq ◽  
Irfan Anjum ◽  
Catalin Iulian Pruncu ◽  
Muhammad Amjad ◽  
M. Saravana Kumar ◽  
...  
Keyword(s):  
Skin Diseases ◽  
Cryogenic Treatment ◽  
Sustainable Manufacturing ◽  
Health And Safety ◽  
Minimum Quantity Lubrication ◽  
Solid Lubricants ◽  
Cryogenic Cooling ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
Sustainable Machining

Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

Sign in / Sign up

Export Citation Format

Share Document