scholarly journals Empirical Models for Surface Roughness and Topography in 5-Axis Milling Based on Analysis of Lead Angle and Curvature Radius of Sculptured Surfaces

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 932
Author(s):  
Michał Gdula
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Curvature Radius ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Inconel 718 Alloy ◽  
Milling Cutter ◽  
Axis Orientation ◽  
Variable Curvature ◽  
Tool Axis

The orientation of the tool axis and the variable curvature of the machined profile of a sculptured surface have a significant impact on the roughness and topography of the surface in the process of 5-axis milling by means of a toroidal milling cutter. The selection of the orientation of the toroidal milling cutter axis relative to the radius of curvature of the machined surface profile is very important as it can provide a better surface quality and an even distribution of roughness parameters. In this paper, an attempt to carry out model tests to obtain mathematical relationships was made. These relationships were to determine the impact of the tool axis orientation and the variable curvature radius of the machined profile on the surface roughness and its topography in the 5-axis milling process of sculptured surfaces. The tests were conducted on an example of a turbine blade made of Inconel 718 alloy. A measurable effect of the work undertaken was the development of model relationships that can be applied in specialized modules of CAM (Computer Aided Manufacturing) systems supporting the programming of 5-axis machining of sculptured surfaces. The models developed will also make it possible to obtain an evenly distributed roughness on the machined sculptured surface, especially on the surface of the turbine blades of the Inconel 718 alloy, as indicated by the results of the tests carried out.

scholarly journals Effect of kinematic and geometric parameters on the cut layer in a 5-axis machining of the sculptured surfaces

Mechanik ◽  
2017 ◽  
Vol 90 (12) ◽  
pp. 1116-1119
Author(s):  
Michał Gdula ◽  
Jan Burek
Keyword(s):  
Geometric Parameters ◽  
Curvature Radius ◽  
Sculptured Surface ◽  
Simulation Studies ◽  
Sculptured Surfaces ◽  
Axis Orientation ◽  
Convex Surfaces ◽  
Orientation Parameters ◽  
Toroidal Cutter

Results of simulation studies made using the direct CAD method are presented. The significance of the influence of the toroidal cutter axis orientation parameters and curvature radius of the sculptured surface on the cut layer in a 5-axis milling of the convex-concave and concave-convex surfaces, was assessed.

scholarly journals Effect of the lead angle and the radius of curvature on the cutting forces in a 5-axis milling of sculptured surfaces

Mechanik ◽  
2018 ◽  
Vol 91 (1) ◽  
pp. 18-22
Author(s):  
Michał Gdula ◽  
Jan Burek
Keyword(s):  
Turbine Blade ◽  
Convex Surface ◽  
Experimental Studies ◽  
Surface Profile ◽  
Radius Of Curvature ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Inconel 718 Alloy ◽  
Machined Surface ◽  
Lead Angle

Experimental studies are presented, were conducted that aimed at determining the mathematical models of the influence of the lead angle and the radius of curvature of the profile of machined sculptured surface on the components of the cutting force. The object of the experimental studies was a convex and concave surface of a turbine blade of Inconel 718 alloy. The toroid cutter was used for the tests. Based on the results of the study it was found that the lead angle in the machining of the convex surface and concave turbine blade should be continuously varied with the change of radius of curvature in the direction of the machined surface profile.

scholarly journals The influence of electrode infeed in finishing wire electrical discharge machining process on disks fir tree slot accuracy

Mechanik ◽  
2018 ◽  
Vol 91 (10) ◽  
pp. 915-917
Author(s):  
Jan Burek ◽  
Robert Babiarz ◽  
Marcin Płodzień ◽  
Jarosław Buk
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Inconel 718 Alloy ◽  
Shape Accuracy ◽  
Finishing Machining

The article presents the effect of electrode infeed in finishing machining of disk fir tree slots made of Inconel 718 alloy on shape accuracy and surface roughness in WEDM (wire electrical discharge machining).

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

Modeling and Control of Contouring Errors for Five-Axis Machine Tools—Part I: Modeling

2009 ◽  
Vol 131 (3) ◽  
Author(s):  
Burak Sencer ◽  
Yusuf Altintas ◽  
Elizabeth Croft
Keyword(s):  
Robust Control ◽  
Machine Tools ◽  
Error Model ◽  
Rigid Body Dynamics ◽  
Sculptured Surfaces ◽  
Axis Orientation ◽  
Modeling And Control ◽  
Joint Coordination ◽  
Tool Axis ◽  
Five Axis

Aerospace, die, and mold industries utilize parts with sculptured surfaces, which are machined on five-axis computer numerical controlled machine tools. Accurate path tracking for contouring is not always possible along the desired space curves due to the loss of joint coordination during the five-axis motion. This two-part paper presents modeling and robust control of contouring errors for five-axis machines. In Part I, two types of contouring errors are defined by considering the normal deviation of tool tip from the reference path, and by the normal deviation of the tool axis orientation from the reference orientation trajectory defined in the spherical coordinates. Overall contouring errors are modeled during five-axis motion that has simultaneous translation and rotary motions. The coupled kinematic configuration and the rigid body dynamics of all five drives are considered. The contouring error model is experimentally validated on a five-axis machine tool. The error model developed in this paper is then used for simultaneous, real-time robust control of all five drives in Part II.

Performance evaluation of graphene added nanofluids and self-lubricating tools in machining Inconel 718

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Amrita Maddamasetty ◽  
Kamesh Bodduru ◽  
Siva Bevara ◽  
Rukmini Srikant Revuru ◽  
Sanjay Kumar
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Solid Lubricant ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Fluid ◽  
Superior Performance ◽  
Dry Machining ◽  
Inconel 718 Alloy ◽  
Content Type

Purpose Inconel 718 is difficult to machine due to its high toughness and study hardenability. Though the use of cutting fluids alleviates the problem, it is not sustainable. So, supply of a small quantity of specialized coolant to the machining zone or use of a solid lubricant is a possible solution. The purpose of the present work is to improve machinability of Inconel718 using graphene nanoplatelets. Design/methodology/approach In the present study, graphene is used in the machining of Inconel 718 alloy. Graphene is applied in the following two forms: as a solid lubricant and as an inclusion in cutting fluid. Graphene-based self-lubricating tool and graphene added nanofluids are prepared and applied to turning of Inconel 718 at varying cutting velocities. Performances are compared by measuring cutting forces, cutting temperature, tool wear and surface roughness. Findings Graphene, in both forms, showed superior performance compared to dry machining. In total, 0.3 Wt.% graphene added nanofluids showed the lowest cutting tool temperature and flank wear with 44.95% and 83.37% decrease, respectively, compared to dry machining and lowest surface roughness, 0.424 times compared to dry machining at 87 m/min. Originality/value Graphene could improve the machinability of Inconel 718 when used in tools as a solid lubricant and also when used as a dispersant in cutting fluid. Graphene used as a dispersant in cutting fluid is found to be more effective.

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