Sequential Laser Mechanical Microdrilling of Inconel 718 Alloy

2011 ◽  
Vol 133 (1) ◽  
Author(s):  
M. M. Okasha ◽  
P. T. Mativenga ◽  
L. Li
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Hole Drilling ◽  
Drilling Process ◽  
Inconel 718 Alloy ◽  
Step Process ◽  
Pilot Hole ◽  
Burr Size ◽  
New Approaches ◽  
Drilling Method

Mechanical microdrilling of nickel-based aerospace alloys suffers from premature drill breakage due to the fragile nature of the microdrill. Additionally, burr size reduction in both macro- and microscales has become one of the key problems in the drilling process. This paper presents a new method to microdrill Inconel 718 alloy using laser followed by mechanical drilling (sequential drilling). The aim of this research was to understand and evaluate the capability of using sequential laser mechanical drilling method as an effective and efficient method in drilling difficult-to-cut metals. Two new approaches were developed, namely, a two-step process of laser pilot drilling followed by twist drilling and a three-step process of laser pilot hole drilling followed by mechanical pilot drilling and then twist drilling. The holes produced by the new approaches were compared with those by mechanical microdrilling (pilot drilling and then twisting drilling). The results show that mechanical drilling eliminates the laser drilling defects. Furthermore, while large nonuniform burrs with attached cap were found in pure mechanical drilling, 75% reduction in burr size was achieved with the complimentary sequential drilling technology. Additionally, when compared with purely mechanical microdrilling, the new drilling method resulted in 240–430% tool life increase. Thus, the new drilling method presents an opportunity for industry to extend tool life and decrease burr.

Application of EDM Hole-Drilling Method to the Measurement of Residual Stress in Tool and Carbon Steels

2006 ◽  
Vol 128 (3) ◽  
pp. 468-475 ◽  
Author(s):  
Hwa-Teng Lee ◽  
Joachim Mayer ◽  
Fu-Chuan Hsu ◽  
Werner P. Rehbach ◽  
Thomas Weirich ◽  
...  
Keyword(s):  
Electron Microscopy ◽  
Residual Stress ◽  
Tool Steel ◽  
White Layer ◽  
Cold Work ◽  
Carbon Steels ◽  
Hole Drilling ◽  
Drilling Process ◽  
Hole Drilling Method ◽  
Drilling Method

This study adopts the application of the electrodischarge machining (EDM) hole-drilling method to the measurement of residual stress in AISI D2 cold work tool steel, AISI H13 hot work tool steel, and AISI 1045 medium carbon steel. A calibration procedure based on the thermal conductivity of the material is conducted to compensate for the additional compressive stress induced in the workpiece by the EDM hole-drilling operation. Since the formation of this white layer influences the magnitude of the induced stress, the scanning electron microscopy, transmission electron microscopy, and nanoindentation techniques are used to examine the microstructure and hardness of the white layer resolidified on the EDMed surface. The experimental results reveal that combination of the hole-drilling strain-gage method (ASTM standard E837) with an EDM drilling process provides the effective means of determining the residual stress in materials with high hardness and good wear resistance.

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

Graphene nanoplatelets as additives to MQL for improving tool life in machining Inconel 718 alloy

Wear ◽  
2021 ◽  
pp. 203656
Author(s):  
Rachele Bertolini ◽  
Andrea Ghiotti ◽  
Stefania Bruschi
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Graphene Nanoplatelets ◽  
Inconel 718 Alloy

scholarly journals On High-precision Subpixel-based Drilling Technique for Suture Needles with Thread

2014 ◽  
Vol 8 (1) ◽  
pp. 607-612
Author(s):  
Tiebo Sun ◽  
Hong Li
Keyword(s):  
Edge Detection ◽  
High Precision ◽  
Noise Suppression ◽  
Hole Drilling ◽  
Drilling Process ◽  
Structural Elements ◽  
Spatial Moments ◽  
Automated Production ◽  
Fitting Method ◽  
Drilling Method

In order to improve the automation of end-hole drilling process in the production of suture needles with thread, a high-precision subpixel-based drilling method is proposed. According to the edge detection principle in mathematical morphology, combined with the characteristics of the magnified images of the ends of suture needles to be drilled, the morphological edge detection operators with variable structural elements are constructed to achieve noise suppression and fully extract the detailed information of edges of images of needle end holes to be drilled. Then, the subdivision method of spatial moments is adopted to realize the subpixel positioning of pixel-level edges. Finally, least squares fitting method is used to achieve the high-precision positioning of center of needle end hole to be drilled. The experimental results of the 0.5 mm needle samples show that the drilling method proposed in this study has a concentricity error no more than ± 0.2 μm and an average drilling time of 0.65S. Moreover, the method also boasts good real-time performance and stability and meets the automated production needs of drilling process of suture needles with thread.

Influence of the Coated Carbide Grade on the Cutting Tool Life When Machining Inconel 718

2016 ◽  
Vol 674 ◽  
pp. 271-276
Author(s):  
Tomáš Bakša ◽  
Michal Morávek ◽  
Miroslav Zetek
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cutting Tools ◽  
High Heat ◽  
Nuclear Industry ◽  
Inconel 718 Alloy ◽  
The Right ◽  
Coated Carbide ◽  
Milling Tools

This article deals with the machining of Inconel 718 alloy. In the research, several carbide milling tools with different carbide grades and coatings were used. The main aim is compare all cutting tools in terms of their cutting tool life during machining super alloy Inconel 718. This material is used for highly stressed components in the nuclear industry, such as combustion turbine. Due to its rapid hardening and high heat generation, it is very problematic to machining. The right choice of appropriate carbide grade is necessary to achieve high-quality cutting wedge, which is important for good adhesion of the coating. The results of this work will be used for further research and development of cutting tools for machining Inconel 718.

STUDY OF THE DRILLING PROCESS USED IN THE HOLE-DRILLING METHOD THROUGH THRUST FORCE MEASUREMENT AND TOOL WEAR ANALYSIS

2015 ◽  
Author(s):  
Rodrigo Blödorn ◽  
Mariana Tiemi Tamura ◽  
Rodrigo Alberto Henke ◽  
Matias Roberto Viotti ◽  
Armando Albertazzi Gonçalves Jr. ◽  
...  
Keyword(s):  
Tool Wear ◽  
Thrust Force ◽  
Force Measurement ◽  
Hole Drilling ◽  
Drilling Process ◽  
Hole Drilling Method ◽  
Wear Analysis ◽  
Drilling Method

scholarly journals An Investigation of Tool Performance in Interrupted Turning of Inconel 718

2018 ◽  
Vol 237 ◽  
pp. 02008
Author(s):  
Tadeusz Chwalczuk ◽  
Martyna Wiciak ◽  
Agata Felusiak ◽  
Piotr Kieruj
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Burr Size ◽  
Tool Performance ◽  
Interrupted Turning

The paper presents the result of an investigation of cemented carbides cutting tools performance in interrupted turning of Inconel 718. The discussion is based on case study revealed from industry experience. The spacing created for operational reasons cause interruption in turning process what has crucial effect on tool life and wear. Furthermore cutting parameters and tool geometry have significant influence on creating burr at the edge of spacing which leads dimensional deviation. The research based on two stages, preliminary and modelling, was introduced. In the first an effect of cutting speed, feed, depth of cut, rake angle and tool major cutting edge angle on wear and burr size was investigated. The second step was a regression based modelling of major parameter influence on various process aspects such as values of forces, tool wear and burr size. It was found that the consequential effect on plastic deformation of edge and tool performance have depth of cut. It also has been proven that higher cutting speed, lower values of angles provides better quality of machined element. The paper gives recommendations for turning parameters selection to acceptable burr forms, tool life and process performance.

Mikrotiefbohren mit Laserpilotbohrungen*/Micro drilling with laser pilot holes - Laser pre-drilling as guidance for deep hole drilling in demanding surface geometries

2018 ◽  
Vol 108 (01-02) ◽  
pp. 76-80
Author(s):  
S. Michel ◽  
D. Prof. Biermann
Keyword(s):  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Process Chain ◽  
Deep Hole Drilling ◽  
Pilot Hole ◽  
Multi Stage ◽  
Micro Drilling ◽  
Drilling Unit ◽  
Stage Process

Tiefbohrungen erfordern bei anspruchsvollen Anbohrsituationen speziell angepasste Bohrbuchsen oder eine mehrstufige Prozesskette aus Planfräsen, Pilotbohren und Tiefbohren. Mit einem hybriden Maschinenkonzept, bestehend aus einem Laser und einer konventionellen Tiefbohreinheit, lässt sich die Prozesskette deutlich verkürzen. Im Rahmen dieses Artikels wird der Laserpilotbohrprozess für den Edelstahl 1.4404 untersucht und die Verfahrenskombination bei mehreren Anbohrsituationen umgesetzt.   Deep hole drilling requires special drill bushes or a multi-stage process chain of face milling, pilot hole drilling and deep hole drilling for demanding surface geometries. With a hybrid machine concept, consisting of a laser and a conventional deep hole drilling unit, the process chain can be significantly shortened. Within the scope of this article, the laser pilot hole drilling process for AISI 316L is investigated and the process combination for several surface geometries is implemented.

scholarly journals Wear Analysis of gun barrel drill blade in 1.0503 steel drilling process in Milpro HG12 oil environment with addition of ultra-dispersive copper particles and copper oxides

2020 ◽  
Author(s):  
Kazimierz Rychlik ◽  
Cezary Senderowski
Keyword(s):  
Friction Pair ◽  
Copper Oxides ◽  
Hole Drilling ◽  
Drilling Process ◽  
Technological Parameters ◽  
Pilot Hole ◽  
Copper Particles ◽  
Gun Barrel ◽  
Operational Tests ◽  
Wear Indicator

The paper presents construction solutions for guiding a single-sharp barrel drill blade during drilling deep holes, with an analysis of construction and technological problems for two ways of inserting the drill into the processed material in the first stage of drilling - using a pilot hole or guide sleeve. During the implementation of the technological process of deep drilling of holes with barrel drills using a vertical numerical milling machine FNE 40NC AVIA, the kinematics of the object-tool system (P-N) and other technological parameters affecting the execution of pilot holes in strictly defined technological operations were analyzed. The course of operational tests carried out using two types of cooling-lubricating agents - Milpro HG12 oil without and with the addition of ultra-dispersive copper particles and copper oxides (0.05 ÷ 0.6 µm), Panther GP-1 (PWPH PantherOil Poland) in a ratio of 1 to 100 is characterized. Based on the performed drilling of through holes in 1.0503 steel with EB80 drills with a diameter Dc = 8 mm, made of cemented carbide K15 (WC 94%, Co 6%), the course of wear of the barrel drill blade on the total drilling path Lw = 8000 mm for 112 was determined through holes and Kw geometric wear indicator of the drill bit. The obtained results of wear were compared with the results of tribological tests. with the use of cooling lubricants, under the conditions of friction involving 1.0503 steel with tungsten carbide, of chemical composition as K15. The material and technological conditions of abrasive wear of a particular friction pair are the same as for operational tests of the barrel drill blade wear at deep hole drilling.

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