Investigation of machining performance in high-pressure jet assisted turning of Inconel 718: An experimental study (original) (raw)
Related papers
Investigation on Machining Performance of Inconel 718 in High Pressure Cooling Conditions
Strojniski Vestnik Journal of Mechanical Engineering, 2012
The paper deals with experimental investigation on machinability of Inconel 718 in conventional and alternative high pressure cooling conditions. The experiments are designed according to Taguchi L18 orthogonal array based on three levels of cutting speed, feed rate and fluid pressure and two levels of depth of cut. The cutting forces and tool flank wear were measured, while turning Inconel 718 workpieces, using (Ti, Al)N+TiN coated CNMG0812 carbide cutting tools. In order to determine the importance of cutting parameters on tool flank wear and cutting forces, ANOVA (Analysis of variance) was employed. Moreover, with multi regression analysis, empirical equations that indicate relation between tool flank wear and cutting forces with machining parameters were defined. The experiment results have proven that the tool flank wear and cutting forces considerably decrease with the delivery of high pressure coolant to the cutting zone. Moreover, ANOVA results also indicate that high pressure cooling has a significant beneficial effect on cutting tool life.
Proceedings of the …, 2008
The use of high-pressure cutting fluids has been shown to increase tool life or enable higher cutting speeds to be used when machining advanced aerospace materials such as Inconel 718. Cutting fluids act to provide cooling and to reduce friction between the tool and the chip. When supplied at high pressure, greater cooling and penetration of the fluid into the interface between the tool and the chip occur, when compared to conventional flood supply. Both these factors have the potential to alter the resulting surface integrity of the machined component. Following a brief review of the general machinability of Inconel 718, a series of experiments examining the effects of varying the cutting fluid supply pressure and direction of the jet are detailed when finish turning.
New trends in cutting technologies: application of high pressure jet assisted machining
High Pressure Jet Assisted Machining (HPJAM) in turning is a hybrid machining method in which a high pressure jet of cooling and lubrication fluid is directed to the contact zone between chip and cutting tool. It uses in highly productive processes of chip removal - roughing and semi-machining. This paper shows that the application of HPJAM offers great advantages in regarding of materials machinability. Workpiece material used in experimental research in turning process was the construction carbon steel C45E with hardness of 45 HRc and alloyed bearings steel with high resistance to wear 100Cr6 and hardness of 62 HRc. Experimental researches are performed, and material machinability in metal cutting is analyzed.
Tribology in Industry
High Pressure Jet Assisted Machining (HPJAM) in turning is a hybrid machining method in which a high pressure jet of cooling and lubrication fluid, under high pressure (50 MPa), leads to the zone between the cutting tool edge and workpiece. An experimental study was performed to investigate the capabilities of conventional and high pressure cooling (HPC) in the turning of hard-to-machine materials: hard-chromed and surface hardened steel Ck45 (58 HRc) and hardened bearing steel 100Cr6 (62 HRc). Machining experiments were performed using coated carbide tools and highly cutting speed. Experimental measurements were performed for different input process parameters. The cooling capabilities are compared by monitoring of tool wear, tool life, cooling efficiency, and surface roughness. Connection between the tool wear and surface roughness is established. Experimental research show that the hard turning with carbide cutting tools and HP supply CLF provides numerous advantages from the techno-economic aspect: greater productivity, reduce of temperature in the cutting zone, improved control chip formation, extended tool life, low intensity of tool wear, surface roughness in acceptable limits, significant reduce of production costs related to the CLF.
The machinability of nickel-based alloys in high-pressure jet assisted (HPJA) turning
Metalurgija, 2013
Due to their mechanical, thermal and chemical properties, nickel-based alloys are generally included among materials that are hard to machine. An experimental study has been performed to investigate the capabilities of conventional and high-pressure jet assisted (HPJA) turning of hard-to-machine materials, namely Inconel 718. The capabilities of different hard turning procedures are compared by means of chip breakability. The obtained results show that HPJA method offers a significant increase in chip breakability, under the same cutting conditions (cutting speed, feed rate, depth of cut).
Optimization of high-pressure jet assisted turning process by Taguchi method
Advances in Production Engineering & Management, 2013
This paper outlines the Taguchi optimization methodology, which is applied to optimize cutting parameters in high-pressure jet assisted turning when machining Inconel 718. Turning parameters evaluated are the diameter of the nozzle Dn, the pressure of the jet P, the cutting speed Vc, the feed rate f and the distance between the impact point of the jet and the cutting edge d. The experiments were conducted by using L27(3 13) orthogonal array as suggested by Taguchi. Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) are employed to analyze the effect of high-pressure jet assisted turning parameters on the main cutting force and surface roughness, in other words to find optimal levels of the process parameters. The study shows that the Taguchi method is suitable to solve the stated problem with minimum number of trials.
Analysis of Cutting Forces in High Speed Turning of Inconel 718 by using Ceramic Tools
The paper presents an experimental investigation of cutting forces of super alloy Inconel 718 during high speed turning using advanced ceramic grade KYS25 and KYS30 inserts with three different nose radii. The effect of machining parameters on cutting forces was investigated in dry machining. Firstly varying one input parameter speed v=100-450m min-1, f=0.25mm rev-1 and d=0.75 is kept constant. Second varying f=0.05 to 0.40 mmrev-1, Vc=25-mmin-1 and d=0.75mm is kept constant, Finally varying d=0.35-1.5mm,v=250 mmin-1 and f=0.25mmrev-1 is kept constant. The result show that KYS30 rhomboid shaped insert is good surface finish and lower cutting forces in between v=100 -200 mmin-1 as compared to KYS25 insert.
International Journal on Interactive Design and Manufacturing (IJIDeM), 2020
Cryogenic cooling is attributed as a green option to counter the high temperatures developed in machining process. The parameters specific to the cryogenic cooling such as jet radius and jet location have controlling influence on the machining performance. Inconel 718 is one of the most prominent aeronautic alloys, mainly used in the aerospace industry due to its high strength and ability to retain properties at very high temperatures. Inconel 718 is a hard to cut material due its low thermal conductivity and work hardening behavior. The present study that investigates the impact of cryogenic cooling using liquid nitrogen coolant on orthogonal turning of Inconel 718 for different values of jet radius, jet location and cutting speeds. The study incorporated a finite element model to simulate the different machining test conditions. The virtual assessment of cryogenic cutting process is beneficial for the decision making that how these parameters can contribute towards final decision making. The dissipation of heat at cutting edge and presence of jet of cryogenic coolant was simulated and analyzed for different jet radii, jet locations and cutting speeds. The study detected shear angle and evaluated chip compression ratio to understand the plastic deformation and related effects. The study revealed that cutting temperature decreased with increasing flow of LN2 at the cutting edge while the cutting force increased with high flow of coolant.
A Brief Review on Machining of Inconel 718
Materials Today: Proceedings, 2018
Inconel 718 is a novel material introduced in the field of hard to machine material. As it has the ability to withstand tremendous environmental conditions, it is commonly used in combustors, turbocharger rotor and seals, heat exchangers, nuclear reactors, turbine blades, electric submersible well pump and motor shaft and high-pressure vessels. Due to its high strength to weight ratio it is also used in aeronautical and aerospace industry. In recent decade there is a growing demand for cost efficient and ecofriendly machining, many researcher are taking keen interest in development of more advance machining processes. During machining of hard to machine materials, the proper selection of machining processes and cooling conditions plays a vital role which affects the machining performance. This present review paper focuses on the brief description of different machining operations (turning, milling, and drilling) during machining of Inconel 718. In addition, comparison between different cooling environments (Dry, MQL and Cryogenic) and different aspects of cooling fluids are Presented. Experimental and theoretical observations for tool wear, surface roughness and machining temperature using different types of cutting inserts and cooling environments have been discussed.
Inconel 718 is widely used in space, nuclear and thermal industrial components due to its ability to maintain strength at elevated temperatures. The exploration of the machining parameters of the material can provide a data to the manufacturing engineer to understand the machinability of the Inconel 718. The effect of cutting parameters on machining force can provide required strength from the cutting tool and machine tool to provide stable cutting operation. Also, effect of cutting parameters on chip morphology can provide insight stability of the operation and safety of the operation. This paper presents the results of experimental investigation on the effect of cutting parameters on machining force and chip morphology in CNC Turning Operation of Inconel 718.The results show that the feed is the most significant parameter followed by cutting speed, depth of cut. The results also show that the chips thickness keep on increasing as the cutting speed and depth of cut are increased. The chip formation is mostly affected by the change of cutting speed followed by the depth of cut and the feed rate.