scholarly journals A Study on the Optimal Machining Parameters of the Induction Assisted Milling with Inconel 718

Materials ◽  
2019 ◽  
Vol 12 (2) ◽  
pp. 233 ◽  
Author(s):  
Eun Kim ◽  
Choon Lee
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Force ◽  
Inconel 718 ◽  
Eddy Currents ◽  
Optimization Method ◽  
Machining Parameters ◽  
Element Analysis ◽  
Coated Carbide ◽  
Machining Parameter

This paper focuses on an analysis of tool wear and optimum machining parameter in the induction assisted milling of Inconel 718 using high heat coated carbide and uncoated carbide tools. Thermally assisted machining is an effective machining method for difficult-to-cut materials such as nickel-based superalloy, titanium alloy, etc. Thermally assisted machining is a method of softening the workpiece by preheating using a heat source, such as a laser, plasma or induction heating. Induction assisted milling is a type of thermally assisted machining; induction preheating uses eddy-currents and magnetic force. Induction assisted milling has the advantages of being eco-friendly and economical. Additionally, the preheating temperature can be easily controlled. In this study, the Taguchi method is used to obtain the major parameters for the analysis of cutting force, surface roughness and tool wear of coated and uncoated tools under various machining conditions. Before machining experiments, a finite element analysis is performed to select the effective depth of the cut. The S/N ratio and ANOVA of the cutting force, surface roughness and tool wear are analyzed, and the response optimization method is used to suggest the optimal machining parameters.

Evaluation of Cutting Force and Surface Roughness in Turning of GFRP Using Coated Carbide Insert

2015 ◽  
Vol 813-814 ◽  
pp. 317-321 ◽  
Author(s):  
C. Ramesh Kannan ◽  
P. Padmanabhan ◽  
K.P. Vasanthakumar
Keyword(s):  
Surface Roughness ◽  
Glass Fiber ◽  
Cutting Force ◽  
Chemical Vapour ◽  
Deposition Process ◽  
Depth Of Cut ◽  
Reinforced Plastics ◽  
Coated Carbide ◽  
Machining Parameter ◽  
Carbide Insert

This paper is to evaluate the cutting force and surface roughness in turning of Glass fiber reinforced plastics (E-glass fiber) using coated carbide insert. The comparison of the results with uncoated carbide inserts. The carbide insert is coated by multilayer chemical vapour deposition process, the coating elements are TiN/Al2O3/TiCN. The experiment is carried out in the conventional lathe machine under dry condition by varying the three cutting parameter such as speed, feed and depth of cut. The cutting force is measured using a lathe tool dynamometer and surface roughness are measured by using surf tester.The result of the experiment shows the effect of machining parameter on cutting force and surface roughness. The results have confirmed that the coated carbide insert has better results than uncoated and tool life is increased.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

Machining parameters effect in dry turning of AISI 316L stainless steel using coated carbide tools

2015 ◽  
Vol 231 (4) ◽  
pp. 676-683 ◽  
Author(s):  
Rusdi Nur ◽  
MY Noordin ◽  
S Izman ◽  
D Kurniawan
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Power Consumption ◽  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Machining Parameters ◽  
Aisi 316L ◽  
Coated Carbide

Austenitic stainless steel AISI 316L is used in many applications, including chemical industry, nuclear power plants, and medical devices, because of its high mechanical properties and corrosion resistance. Machinability study on the stainless steel is of interest. Toward sustainable manufacturing, this study also includes the power consumption during machining along with other machining responses of cutting force, surface roughness, and tool life. Turning on the stainless steel was performed using coated carbide tool without using cutting fluid. The turning was performed at various cutting speeds (90, 150, and 210 m/min) and feeds (0.10, 0.16, and 0.22 mm/rev). Response surface methodology was adopted in designing the experiments to quantify the effect of cutting speed and feed on the machining responses. It was found that cutting speed was proportional to power consumption and was inversely proportional to tool life, and showed no significant effect on the cutting force and the surface roughness. Feed was proportional to cutting force, power consumption, and surface roughness and was inversely proportional to tool life. Empirical equations developed from the results for all machining responses were shown to be useful in determining the optimum cutting parameters range.

Measurement of roughness on hardened D-3 steel and wear of coated tool inserts

2020 ◽  
pp. 014233122093855
Author(s):  
A Bovas Herbert Bejaxhin ◽  
G Paulraj ◽  
G Jayaprakash ◽  
V Vijayan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
High Speed ◽  
High Carbon Steel ◽  
Numerical Control ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cnc Turning ◽  
Coated Carbide

This research investigation has been carried out in Computer Numerical Control (CNC) turning of 40–50 Hardness Rockwell C (HRC) hardened high chromium high carbon steel (HCHCR-D3) specimen for the findings of surface roughness (Ra) and the tool wear. The HCHCR-D3 steel, which has excellent abrasion and wear resistance, is machined with the physical vapor deposition (PVD) coated carbide (CNMG) turning insert nomenclature based on shape, clearance angle, tolerance and type of tool inserts. The coatings preferred are Titanium Nitrate (TiN), Aluminium Chromium Nitrate (AlCrN) and Latuma for the coating thickness of 3–4μm. The varying input parameters of speed and depth of cut under constant feed rate are used as machining parameters for this CNC turning operation. The machined surface characterization and tool wear have been investigated analytically in this manuscript along with the predicted results of effective stresses and temperatures under dynamic cutting conditions in Deform 3D can be related. The outcomes indicate that the depth of cut and the hardening effect (HRC) are the major influencing parameter on surface roughness. Less tool wear and machining time are obtained by the usage of coated CNMG tool insert for high-speed cutting conditions which results in minimization of wear interruption and growth in surface improvements.

Multi-Objective Optimization of Surface Roughness and Tool Wear in Turning Inconel 718: A Desirability Analysis, Genetic Algorithm and Firefly Algorithm 

2014 ◽  
Vol 592-594 ◽  
pp. 545-549 ◽  
Author(s):  
Shiv Kumar Sharma ◽  
M. Chandrasekaran ◽  
R. Thirumalai
Keyword(s):  
Genetic Algorithm ◽  
Surface Roughness ◽  
Tool Wear ◽  
Process Parameters ◽  
Inconel 718 ◽  
Firefly Algorithm ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Desirability Analysis

In this work, a parameter optimization in turning Inconel 718 for multiple performance characteristics has been attempted. The process parameters viz., cutting speed (v), feed (f) and depth of cut (d) is optimized that minimizes surface roughness (Ra) and tool wear (VB). Response surface methodology (RSM) employing CCD experimental design was used to develop predictive model for Ra and VB. The predictive capability of the model provides the average percentage error as 3.87 % and 5.10% for Ra and VB respectively with maximum percentage error limited to 14.67 %. The data are analysed to study the main effect and interaction effects of machining parameters through surface plot. Feed remains dominating factor. Process parameters are optimized for single and multiple objectives using three different techniques viz., statistical and mathematical approach based desirability analysis (DA) and soft computing based genetic algorithm (GA) and firefly algorithm (FA). The results are compared.

scholarly journals Dry turning of X2CrNi18-09 using coated carbide tools: modelling and optimization of multiple performance characteristics

Mechanika ◽  
2019 ◽  
Vol 25 (6) ◽  
pp. 487-500
Author(s):  
Septi Boucherit ◽  
Sofiane Berkani ◽  
Mohamed Athmane Yallese ◽  
Abdelkrim Haddad ◽  
Salim Belhadi
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Removal Rate ◽  
Desirability Function ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Parameters ◽  
Coated Carbide

The present paper investigates the cutting parameters pertaining to the turning of X2CrNi18-09 austenitic stainless steel that are studied and optimized using both RSM and desirability approaches. The cutting tool inserts used are the CVD coated carbide. The cutting speed, the feed rate and the depth of cut represent the main machining parameters considered. Their influence on the surface roughness and the cutting force are further investigated using the ANOVA method. The results obtained lead to conclude that the feed rate is the surface roughness highest influencing parameter with a contribution of 89.69%.The depth of cut and the feed rate are further identified as the most important parameters affecting the cutting force with contributions of 46.46% and 39.04% respectively. The quadratic mathematical models presenting the progression of the surface roughness and the cutting force and based on the machining parameters considered (cutting speed, feed rate and depth of cut) were obtained through the application of the RSM method. They are presented and compared to the experimental results. Good agreement is found between the two sections of the investigation. Furthermore, the flank wear of the CVD-coated carbide tool (GC2015) is found to increase with both cutting speed and cutting time. A higher tool life represented by t=44min is observed at cutting speed, feed rate and depth of cut of 280m/min,0.08mm/rev and 0.2mm respectively. Moreover and at low cutting speeds, the formation of micro weld is noticed and leads to an alteration of the surface roughness of the work piece. Finally, optimizing the machining parameters with the objective of achieving an improved surface roughness was accomplished through the application of the Desirability Function approach. This enabled to finding out the optimal parameters for maximal material removal rate and best surface quality for a cutting speed of 350m/min, a feed rate of 0.088 mm/rev and a depth of cut of 0.9mm.  

Influence of cryogenic treatment of cutting tool inserts on tool wear and surface roughness during milling of Inconel 718

2020 ◽  
Author(s):  
Ivan Sunit Rout ◽  
P. Pal Pandian ◽  
Manish Mathew ◽  
Kevin Lobo Ivan ◽  
Shomyajit Misra
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Cryogenic Treatment

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

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