scholarly journals A Combined Experimental and Optimization Model to Improve the Machinability of Nimonic C-263 Superalloy

2020 ◽  
Author(s):  
Prashant Jadhav ◽  
Chinmaya Prasad Mohanty
Keyword(s):  
Process Parameters ◽  
Cutting Speed ◽  
Sem Analysis ◽  
Depth Of Cut ◽  
Process Conditions ◽  
Optimization Of Process Parameters ◽  
Excellent Mechanical Property ◽  
Single Response ◽  
Optimal Set ◽  
Super Alloy

Nickel based superalloys finds extensive usage in manufacturing of intricate part shapes in gas turbine, aircraft, submarine, and chemical industries owing their excellent mechanical property and heat resistant abilities. However, machining of such difficult-to-machine alloys up to the desired accuracy and preciseness is a complex task owing to a rapid tool wear and failure. In view of this, present work proposes an experimental investigation and optimization of process parameters of the cryogenic assisted turning process during machining of Nimonic C-263 super alloy with a multilayer CVD insert. Taguchi’s L-27 orthogonal array is used plan the experiments. Effect of input parameters viz. cutting speed (N), cutting feed (f), depth of cut (d) are studied on responses viz. surface roughness (SR), nose wear (NW) and cutting forces (F) under hybrid cryogenic (direct+indirect) machining environment. A scanning electron microscope (SEM) analysis is carried out to explore the post-machining outcomes on the performance measures. The multiple responses are converted in to single response and ranked according to Taguchi based gray relational grade (TGRG). Feed rate (f) is found to be the most influential parameter from the analysis of variance of GRG. The means of GRG for each level of process parameters are used to improve the optimal process parameters further. Finally, the confirmative experiment is performed with these optimal set of process parameters which showed an improvement of 9.34% in the value of GRG. The proposed work can be beneficial to choose ideal process conditions to enhance the performance of turning operation.

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.

scholarly journals Experimental Investigation and Optimization of Machining Parameters in Turning of Aluminum Alloy 075-T651

2021 ◽  
Vol 27 (4) ◽  
pp. 296-305
Author(s):  
Arpit Srivastava ◽  
Mukesh Kumar Verma ◽  
Ramendra Singh Niranjan ◽  
Abhishek Chandra ◽  
Praveen Bhai Patel
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Cutting Speed ◽  
Radial Force ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimization Of Process Parameters ◽  
Feed Force ◽  
Aluminum 7075 ◽  
Aluminum Alloy 7075

Abstract Aluminum alloy 7075-T651 is a widely used material in the aviation, marine, and automobile sectors. The wide application marks the importance of this material’s research in the manufacturing field. This research focuses on optimizing input process parameters of the turning process in the machining of Aluminum 7075-T651 with a tungsten carbide insert. The input machining parameters are cutting speed, feed, and depth of cut for the output response parameters cutting force, feed force, radial force, material removal, and surface roughness of the workpiece. For optimization of process parameters, the Taguchi method, with standard L9 orthogonal array, is used. ANOVA is applied to obtain signifi-cant factors and optimal combinations of process parameters.

scholarly journals Experimental Optimization of Process Parameters in CuNi18Zn20 Micromachining

Micromachines ◽  
2021 ◽  
Vol 12 (11) ◽  
pp. 1293
Author(s):  
Andrea Abeni ◽  
Alessandro Metelli ◽  
Cristian Cappellini ◽  
Aldo Attanasio
Keyword(s):  
Process Parameters ◽  
Optimization Technique ◽  
Cutting Speed ◽  
Surface Finishing ◽  
Depth Of Cut ◽  
Micro Machining ◽  
Industrial Sectors ◽  
Optimization Of Process Parameters ◽  
The Cost ◽  
Machining Optimization

Ultraprecision micromachining is a technology suitable to fabricate miniaturized and complicated 3-dimensional microstructures and micromechanisms. High geometrical precision and elevated surface finishing are both key requirements in several manufacturing sectors. Electronics, biomedicals, optics and watchmaking industries are some of the fields where micromachining finds applications. In the last years, the integration between product functions, the miniaturization of the features and the increasing of geometrical complexity are trends which are shared by all the cited industrial sectors. These tendencies implicate higher requirements and stricter geometrical and dimensional tolerances in machining. From this perspective, the optimization of the micromachining process parameters assumes a crucial role in order to increase the efficiency and effectiveness of the process. An interesting example is offered by the high-end horology field. The optimization of micro machining is indispensable to achieve excellent surface finishing combined with high precision. The cost-saving objective can be pursued by limiting manual post-finishing and by complying the very strict quality standards directly in micromachining. A micro-machining optimization technique is presented in this a paper. The procedure was applied to manufacturing of main-plates and bridges of a wristwatch movement. Cutting speed, feed rate and depth of cut were varied in an experimental factorial plan in order to investigate their correlation with some fundamental properties of the machined features. The dimensions, the geometry and the surface finishing of holes, pins and pockets were evaluated as results of the micromachining optimization. The identified correlations allow to manufacture a wristwatch movement in conformity with the required technical characteristics and by considering the cost and time constraints.

Optimization of Process Parameters during Milling of Friction Stir Processed GFRP Composites

2014 ◽  
Vol 984-985 ◽  
pp. 297-303
Author(s):  
Bakthavachalu Balamugundan ◽  
Loganathan Karthikeyan
Keyword(s):  
Process Parameters ◽  
Statistical Significance ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
End Mill ◽  
Gfrp Composites ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Solid Carbide ◽  
Overall Performance

In this study, GFRP plates were friction stir processed at three different feed rates (15 mm/min, 20 mm/min and 25 mm/min) and at a constant spindle speed of 1500 rpm with an aim to enhance their microstructural properties. The friction stir processed plates were then subjected to milling with solid carbide K6 end mill tools. Millings trials were carried out using a Taguchi’s L9 orthogonal array under three input parameters such as cutting speed, feed and depth of cut each having three levels. The statistical significance of the process parameters was estimated using signal to noise (S/N) ratio and Analysis of Variance (ANOVA). The study showed that cutting speed during milling and feed rate during FSP contributed to the overall performance which was assessed in terms of surface roughness and delamination factor.

scholarly journals Optimization of Process Parameters for Turning Hastelloy X under Different Machining Environments Using Evolutionary Algorithms: A Comparative Study

2021 ◽  
Vol 11 (20) ◽  
pp. 9725
Author(s):  
Vinothkumar Sivalingam ◽  
Jie Sun ◽  
Siva Kumar Mahalingam ◽  
Lenin Nagarajan ◽  
Yuvaraj Natarajan ◽  
...  
Keyword(s):  
Process Parameters ◽  
Regression Models ◽  
Research Work ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cryogenic Machining ◽  
Linear Regression Models ◽  
Hastelloy X ◽  
Optimization Of Process Parameters ◽  
Optimal Set

In this research work, the machinability of turning Hastelloy X with a PVD Ti-Al-N coated insert tool in dry, wet, and cryogenic machining environments is investigated. The machinability indices namely cutting force (CF), surface roughness (SR), and cutting temperature (CT) are studied for the different set of input process parameters such as cutting speed, feed rate, and machining environment, through the experiments conducted as per L27 orthogonal array. Minitab 17 is used to create quadratic Multiple Linear Regression Models (MLRM) based on the association between turning parameters and machineability indices. The Moth-Flame Optimization (MFO) algorithm is proposed in this work to identify the optimal set of turning parameters through the MLRM models, in view of minimizing the machinability indices. Three case studies by considering individual machinability indices, a combination of dual indices, and a combination of all three indices, are performed. The suggested MFO algorithm’s effectiveness is evaluated in comparison to the findings of Genetic, Grass-Hooper, Grey-Wolf, and Particle Swarm Optimization algorithms. From the results, it is identified that the MFO algorithm outperformed the others. In addition, a confirmation experiment is conducted to verify the results of the MFO algorithm’s optimal combination of turning parameters.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

Evaluation of Process Parameters in Machining of AA6063 Alloy

2018 ◽  
Vol 1148 ◽  
pp. 109-114
Author(s):  
M. Balaji ◽  
C.H. Nagaraju ◽  
V.U.S. Vara Prasad ◽  
R. Kalyani ◽  
B. Avinash
Keyword(s):  
Surface Roughness ◽  
Regression Analysis ◽  
Process Parameters ◽  
Single Channel ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Roughness Parameters ◽  
Surface Roughness Parameters ◽  
Aa6063 Alloy

The main aim of this work is to analyse the significance of cutting parameters on surface roughness and spindle vibrations while machining the AA6063 alloy. The turning experiments were carried out on a CNC lathe with a constant spindle speed of 1000rpm using carbide tool inserts coated with Tic. The cutting speed, feed rate and depth of cut are chosen as process parameters whose values are varied in between 73.51m/min to 94.24m/min, 0.02 to 0.04 mm/rev and 0.25 to 0.45 mm respectively. For each experiment, the surface roughness parameters and the amplitude plots have been noted for analysis. The output data include surface roughness parameters (Ra,Rq,Rz) measured using Talysurf and vibration parameter as vibration amplitude (mm/sec) at the front end of the spindle in transverse direction using single channel spectrum analyzer (FFT).With the collected data Regression analysis is also performed for finding the optimum parameters. The results show that significant variation of surface irregularities and vibration amplitudes were observed with cutting speed and feed. The optimum cutting speed and feed from the regression analysis were 77.0697m/min and 0.0253mm/rev. for the minimum output parameters. No significant effect of depth of cut on output parameters is identified.

Statistical Analysis of Process Parameters in Drilling of Al/Al2O3p Metal Matrix Composites

2014 ◽  
Vol 14 (3) ◽  
pp. 171-175 ◽  
Author(s):  
Yashvir Singh ◽  
Amneesh Singla ◽  
Ajay Kumar
Keyword(s):  
Surface Roughness ◽  
Statistical Analysis ◽  
Process Parameters ◽  
Metal Matrix ◽  
Design Method ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Signal To Noise ◽  
Drilling Parameters

AbstractThis paper presents a statistical analysis of process parameters for surface roughness in drilling of Al/Al2O3p metal matrix composite. The experimental studies were conducted under varying spindle speed, feed rate, point angle of drill. The settings of drilling parameters were determined by using Taguchi experimental design method. The level of importance of the drilling parameters is determined by using analysis of variance. The optimum drilling parameter combination was obtained by using the analysis of signal-to-noise ratio. Through statistical analysis of response variables and signal-to-noise ratios, the determined significant factors are depth of cut and drill point angle with the contributions of 87% and 12% respectively, whereas the cutting speed is insignificant contributing by 1% only. Confirmation tests verified that the selected optimal combination of process parameter through Taguchi design was able to achieve desired surface roughness.

Performance Evaluation of PVD and CVD Coated Inserts during End Milling with DRY and MQL Condition

2017 ◽  
Vol 867 ◽  
pp. 165-170
Author(s):  
Isha Srivastava ◽  
Ajay Batish
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Sem Analysis ◽  
Depth Of Cut ◽  
High Cutting Speed ◽  
Cutting Operation ◽  
En 31

The aim of this study were to evaluate the performance of PVD (TiAlN+TiN) and CVD (TiCN+Al2O3+TiN) coated inserts in end milling of EN–31 hardened die steel of 43±1 HRC during dry and MQL (Minimum quantity lubrication) machining. The experiments were conducted at a fixed feed rate, depth of cut and varying cutting speed to measure the effect of cutting speed on cutting force and tool wear of CVD and PVD-coated inserts. The performance of CVD and PVD-coated inserts under dry and MQL condition by measuring the tool wear and cutting force were compared. During cutting operation, it was noticed that PVD inserts provide less cutting force and tool wear as compared to the CVD inserts under both dry as well as the MQL condition because PVD inserts have a thin insert coating and CVD inserts have a thick insert coating, but PVD inserts experience catastrophic failure during cutting operation whereas CVD inserts have a capability for continuous machining under different machining. Tool wear has measured by SEM analysis. The result shows that MQL machining provides the optimum results as compared to the dry condition. MQL machining has the ability to work under high cutting speed. As the cutting speed increases the performance of dry machining was decreased, but in MQL machining, the performance of the inserts was increased with increases of cutting speed. MQL machining generates less cutting force on the cutting zone and reduces the tool wear which further increase the tool life.

Optimization of Process Parameters in the Turning Operation of Inconel 625

2019 ◽  
Vol 969 ◽  
pp. 756-761
Author(s):  
Hari Vasudevan ◽  
Ramesh Rajguru ◽  
Moeiz Shaikh ◽  
Arsalan Shaikh
Keyword(s):  
Feed Rate ◽  
Cutting Speed ◽  
Influential Factor ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Turning Operation ◽  
Wide Range ◽  
Coated Carbide ◽  
Taguchi’S Design Of Experiments ◽  
Super Alloy

Many difficult to machine materials, such as Inconel 625Ni-based super alloy, are uncommon class of metallic materials with exceptional combination of greater thermal strength, toughness and resistance to deterioration. They have extensive applications in the manufacturing of new aero-engines, besides its enormous uses in marine, chemical and oil & petrochemical industries. In the context of its wide range of applications, there is a need for efficiently processing better methods in the manufacturing of such difficult to machine materials. This study consists of the turning operation of Ni-based super alloy Inconel 625 without coolant, carried out by physical vapour deposition (PVD) coated carbide inserts. The response parameters, such as surface roughness and material removal rate were evaluated in terms of cutting speed, feed rate and depth of cut. Sixteen experiments were carried out, based on Taguchi's Design of Experiments using orthogonal array. The resulting analysis was done based on response graph. The experimental results revealed that the feed rate was the most influential factor, followed by the depth of cut and cutting speed. The optimal parameters achieved were cutting speed of 90 m/min, the feed rate of 0.35 mm/rev and the depth of cut 0.2 mm.

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