Assessment of Plasma Enhanced Machining for Improved Machinability of Inconel 718

1997 ◽  
Vol 119 (1) ◽  
pp. 125-129 ◽  
Author(s):  
J. W. Novak ◽  
Y. C. Shin ◽  
F. P. Incropera
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Tool Life ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Experimental Results ◽  
Hybrid Machining ◽  
Machining System ◽  
Conventional Machining

An experimental study has been performed to assess the feasibility of using a hybrid machining system to improve the machinability of Inconel 718. An assembled plasma enhanced machining (PEM) system is described, and experimental results obtained from both conventional and plasma enhanced machining of Inconel 718 are compared. Several advantages of PEM over conventional machining are demonstrated, including improvement of surface roughness, lower cutting forces and extended tool life.

A Micromilling Experimental Study on AISI 4340 Steel

2009 ◽  
Vol 407-408 ◽  
pp. 335-338 ◽  
Author(s):  
Jin Sheng Wang ◽  
Da Jian Zhao ◽  
Ya Dong Gong
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Cutting Force ◽  
Spectrum Analysis ◽  
Chip Thickness ◽  
Experimental Results ◽  
Minimum Chip Thickness ◽  
Aisi 4340 Steel ◽  
4340 Steel ◽  
Aisi 4340

A micromilling experimental study on AISI 4340 steel is conducted to understand the micromilling principle deeply. The experimental results, especially on the surface roughness and cutting force, are discussed in detail. It has been found the minimum chip thickness influences the surface roughness and cutting force greatly. Meanwhile, the material elastic recover induces the increase of the axial micromilling force. The average cutting force and its spectrum analysis validate the minimum chip thickness approximation of AISI 4340 is about 0.35μm.

Enhancement of Machinability of Inconel 718 in End Milling through Online Induction Heating of Workpiece

2011 ◽  
Vol 415-417 ◽  
pp. 420-423 ◽  
Author(s):  
AKM Nurul Amin ◽  
Mohammad Ishtiyaq Hossain ◽  
Anayet Ullah Patwari
Keyword(s):  
Tool Life ◽  
Induction Heating ◽  
Inconel 718 ◽  
End Milling ◽  
Heating Temperature ◽  
Phase Transformation Temperature ◽  
Life Tool ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Conventional Machining

Abstract. This paper presents the outcome of a study on heat assisted end milling of Inconel 718 using inducting heating technique conducted to enhance the machinability of the material. The heating temperature maintained below the phase transformation temperature was aimed at softening the top removable material layers. The experimental results of both conventional and heat assisted machining were compared. The machinability of Inconel 718 under these conditions was evaluated in terms of tool life, tool wear morphology and chatter. The advantages of Induction heating is demonstrated by an longer tool life and lower chatter. The study showed that preheated machining facilitates up to 80% increase of tool life over conventional machining conducted using TiAlN coated carbide inserts.

Experimental Investigation to Optimize Tool Life and Surface Roughness in Inconel 718 Machining

2015 ◽  
Vol 31 (13) ◽  
pp. 1683-1691 ◽  
Author(s):  
Farshid Jafarian ◽  
Domenico Umbrello ◽  
Saeid Golpayegani ◽  
Zahra Darake
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Tool Life ◽  
Inconel 718

End-Milling Machinability of Inconel 718

1996 ◽  
Vol 210 (1) ◽  
pp. 11-23 ◽  
Author(s):  
M Alauddin ◽  
M A El Baradie ◽  
M S J Hashmi
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Inconel 718 ◽  
End Milling ◽  
Milling Process ◽  
Machining Parameters ◽  
Life Tests ◽  
Life Values ◽  
Published Research ◽  
Carbide Inserts

Most published research works on machining Inconel 718 have been mainly concerned with turning, while the milling process has received little attention due to the complexity of the process. In this paper a series of end-milling experiments of Inconel 718 has been carried out in order to: (a) optimize cutting variables, (b) investigate tool life values and relationships and (c) investigate surface roughness. The machining parameters have been optimized by measuring cutting forces. Tool life tests have been carried out using carbide inserts and the surface roughness has been analysed.

scholarly journals Effect of laser deweighting on properties of ZL205A aluminum alloy

2021 ◽  
Vol 2137 (1) ◽  
pp. 012033
Author(s):  
Guang Li ◽  
Zhipeng Wei ◽  
Junlong Wang ◽  
Yangyang Zhang ◽  
Chen Wang ◽  
...  
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Aluminum Alloy ◽  
Surface Morphology ◽  
Pulse Laser ◽  
Process Parameters ◽  
Experimental Results ◽  
Matrix Properties ◽  
Before And After ◽  
The Matrix

Abstract In this paper, a nanosecond fiber pulse laser is used to carry out the experimental study on laser weight removal of ZL205A aluminum alloy gyro rotor. By optimizing the process parameters of laser weight removal, better surface morphology was obtained. The effects of surface roughness, metallographic structure and hardness of samples before and after laser deweighting were analyzed. The experimental results show that the laser weight removal does not affect the matrix properties of ZL205A aluminum alloy. The laser de-weight technology is suitable for the balance of ZL205A aluminum alloy gyro rotor.

scholarly journals Optimization of Atomized Spray Cutting Fluid Eco-Friendly Turning of Inconel 718 Alloy Using ARAS and CODAS Methods

2021 ◽  
Author(s):  
Vinothkumar Sivalingam ◽  
Ganeshkumar Poogavanam ◽  
Yuvaraj Natarajan ◽  
Jie Sun
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Tool Life ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Parameter Setting ◽  
Inconel 718 Alloy ◽  
Desirability Index

Abstract Atomized spray cutting fluid (ASCF) is a sophisticated machining technique that achieves higher productivity, enhanced surface quality, extended tool life, and cost benefits. This research aims to analyze the influence of cutting process parameters on Inconel 718 alloy turning in dry and ASCF cutting environments. The critical machining indices such as surface roughness, machining cost, power consumption, and tool life were analyzed concerning these two cooling environments. The cutting parameters were optimized using desirability functional analysis and two types of multicriteria decision making (MCDM) method, such as additive ratio assessment method (ARAS) and combinative distance-based assessment (CODAS) method, were investigated. The composite desirability index (CD) of optimum parameter setting(A2B1C2D2) is improved by 6.34 % compared to the initial parameter setting (A2B1C2D1). The optimum parameters from the MCDM technique are obtained as a cutting speed of 200 m/min, feed rate of 0.08 mm/rev, and depth of cut of 0.2 mm under ASCF environment. ASCF machining significantly minimize the surface roughness, machining cost and power consumption, maximize the tool life by about 16%, 51%, 17% and 48% respectively as compared with dry machining

Multi-Objective Optimization Using Box-Behken of Response Surface Methodology for High-Speed Machining of Inconel 718

2014 ◽  
Vol 629 ◽  
pp. 487-492 ◽  
Author(s):  
Mohd Shahir Kasim ◽  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
E. Mohamad ◽  
Raja Izamshah ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Tool Life ◽  
Feed Rate ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Milling

This study was carried out to investigate how the high-speed milling of Inconel 718 using ball nose end mill could enhance the productivity and quality of the finish parts. The experimental work was carried out through Response Surface Methodology via Box-Behnken design. The effect of prominent milling parameters, namely cutting speed, feed rate, depth of cut (DOC), and width of cut (WOC) were studied to evaluate their effects on tool life, surface roughness and cutting force. In this study, the cutting speed, feed rate, DOC, and WOC were in the range of 100 - 140 m/min, 0.1 - 0.2 mm/tooth, 0.5 - 1.0 mm and 0.2 - 1.8 mm, respectively. In order to reduce the effect of heat generated during the high speed milling operation, minimum quantity lubrication of 50 ml/hr was used. The effect of input factors on the responds was identified by mean of ANOVA. The response of tool life, surface roughness and cutting force together with calculated material removal rate were then simultaneously optimized and further described by perturbation graph. Interaction between WOC with other factors was found to be the most dominating factor of all responds. The optimum cutting parameter which obtained the longest tool life of 60 mins, minimum surface roughness of 0.262 μm and resultant force of 221 N was at cutting speed of 100 m/min, feed rate of 0.15 mm/tooth, DOC 0.5 m and WOC 0.66 mm.

Machining nickel base superalloys: Inconel 718

1998 ◽  
Vol 212 (3) ◽  
pp. 195-206 ◽  
Author(s):  
I A Choudhury ◽  
M A El-Baradie
Keyword(s):  
Tool Life ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Coated Tools ◽  
Nickel Base ◽  
Better Than

A series of machining experiments of Inconel 718 has been carried out using coated and uncoated carbides. The paper describes the effects of cutting variables (speed, feed and depth of cut) on cutting forces and tool life. Carbide tools in the form of 80° rhomboid shaped inserts without any chip breaker have been used at different cutting conditions. The machining parameters have been optimized by measuring cutting forces. Flank wear was considered as the criterion for tool life. A comparison between the uncoated and coated tools has been made using the Taylor's tool life exponents of speed, feed and depth of cut. The tool life of coated tools was not found to be better than that of the uncoated tools.

Investigation on laser-induced oxidation assisted micro-milling of Inconel 718

2020 ◽  
Vol 234 (8) ◽  
pp. 1102-1112 ◽  
Author(s):  
Hongjun Xia ◽  
Guolong Zhao ◽  
Maoshun Hu ◽  
Liang Li ◽  
Aqib Mashood Khan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Wear Mechanism ◽  
Inconel 718 ◽  
Micro Milling ◽  
Hybrid Process ◽  
Hybrid Machining ◽  
Burr Size ◽  
Tool Wear Mechanism ◽  
Coating Delamination

Poor surface quality and rapid tool wear are the main problems in micro-cutting of Inconel 718. In this study, a novel hybrid machining method named laser-induced oxidation assisted micro-milling is proposed to solve the aforementioned problems. A loose oxide layer and a relatively flat sublayer are formed on the material after laser irradiation. Under optimized laser parameters with a scanning speed of 1 mm/s and an average laser power of 4.5 W, the thicknesses of the oxide layer and the sublayer are 24 and 18 μm, respectively. The influence of cutting parameters on milling force, surface roughness, surface quality, and top burr size is studied in detail. Cutting force and thrust force in the proposed hybrid machining process are lower than those in the conventional micro-milling. Results show that for the investigated range of parameters, the optimal feed per tooth and depth of cut in the hybrid process are 3 μm/z and 3 μm, respectively. When using the optimal parameters, the surface roughness of the machined slot bottom is 108.5 nm. The top burr size on the up-milling side and the down-milling side is 26.8 and 36.2 μm, respectively. In addition, the tool wear mechanism is coating delamination in hybrid process, whereas chipping, coating delamination, tool nose breakage, and adhesion are the main tool wear mechanism in the conventional micro-milling. For the same amount of material removal, the proposed hybrid process can decrease the tool wear and enhance the service life of the micro-end mill as compared to conventional micro-milling.

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