Investigation of surface topology in ball nose end milling process of Inconel 718 (original) (raw)
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Journal of Materials Engineering and Performance, 2014
In machining of Inconel 718, various difficulties such as increased tool wear and poor machined surface quality are frequently encountered due to its high temperature strength and poor thermal properties. This work considers the effect of number of passes and the machining environment on the machined surface quality in ball end milling of Inconel 718, which hitherto has not been adequately understood. To this effect, extensive experimentation has been carried out to analyze machined surface quality and integrity in terms of surface roughness, surface damage, and microhardness variation in the machined surfaces. The machined surfaces show formation of distinct bands as a function of instantaneous machining parameters along the periphery of cutting tool edge. A distinct variation is also observed in the measured values of surface roughness and microhardness in these regions. The minimum surface roughness is obtained in the stable cutting zone and it increases toward the periphery of the cutter on band #2 and band #3. Microhardness of depth beneath the machined surface shows that the machining affected zone varies from 60 to 100 lm in ball end milling under various machining conditions.
Effect of ball end milling parameters on surface and subsurface of Inconel-718
International Journal of Basic and Applied Sciences, 2014
Inconel-718 has poor machinability due to this; it is leading to severe low surface integrity. The paper discusses the effect of ball end milling parameters on surface integrity produced during dry and chilled machining environment. In this work, the variable depth of cut concept of Scattergood is used to describe the influence of machining process parameters on the machined surface. Taguchi orthogonal (L8) experiments were designed considering five input parameters. The surface integrity in terms of arithmetic average surface roughness Ra and the microhardness is analysed in this paper. The results show that the dry machining was beneficial for surface integrity.
Advances in Materials and Processing Technologies
In aerospace and submarine industries, mechanical parts are designed & developed using nickel-based alloys, such as Inconel 625. In such applications, severe work hardening occurs, leading to poor surface quality. In this context, this study was conducted using an end mill with PVD TiAlSiN coating, under dry conditions, wherein four input variables were considered. Rotatable CCD technique of DoE was used to conduct the experimental plan. RSM was applied to develop a second-order mathematical model, with roughness parameter and process parameters to establish the relationship between them. ANOVA was carried out to test the significance of the model. From the model, it was observed that both the feed per tooth and radial depth of cut have a significant effect on surface roughness. Further, the interaction between the cutting speed and feed per tooth was also found significant. The study also demonstrated that the coated carbide tool has the potential to eliminate the usage of cutting fluid, thus taking care of the environmental concerns, as far as machining operations are concerned.
Engineering and Technology Journal, 2021
The cutting process is an important process of industrialization. It is requisite to using advantage quality cutting tools in order to preserve the type of product. Coating on the cutting tool has a substantial effect in terms of mechanical properties and the end results of the product. The cutting tool can be manufactured in various material types, but today's cemented tungsten carbide is the most commonly used material in the tool industry because its properties comply with manufacturers' requirements. This study investigates the impact of an Al2O3 coated cutting tool relative to an uncoated cutting tool on the dry cutting process. Different parameters are used in the cutting process when cutting the metal. The cutting parameters used are feed rate and cutting speed, An analysis of the effects of these parameters on the surface roughness. In this analysis, the surface roughness are measured for components turned from steel1040, The L9 Taguchi orthogonal arrays and analyses of variance (ANOVA) was employed to analyze the influence of these parameters. In the case of (uncoated, Al2O3 coated tool), the better surface roughness (SR) with used feed rate (0.05 mm / rev) and cutting speed (140 m/min) where the roughness value was (0.81μm) and (0.78μm) Respectively. The results of this study indicate that the ideal parameters combination for the better surface finish was high cutting speed and low feed rate.
IOP Conference Series: Materials Science and Engineering, 2019
As a part of the cutting process, a researched aspect continuously is surface quality. Based on and using the results of previous research, the present scientific paper addresses the problem of the machined surfaces roughness. The cutting process approached in this study is the end-milling one, and the workpiece material used to carry out the study is the aluminum alloy used in the aerospace industry. The adopted cutting regime imply to keep the cutting speed at a constant value while the cutting parameters: cutting depth and feed per tooth vary with different values. The experimental research carried out by the authors in a prestigious industrial company is complicated and complies with the specific methodology. The conclusions stand based on the interpretation of the results obtained from the experiments which were carried out based on the active experimental type. The confirmation of the obtained results was performed using the profiles and images of the microscopic analysis of t...
An Investigation on Surface Roughness and Tool Wear in Turning Operation of Inconel 718
Journal of Aerospace Technology and Management, 2019
This paper investigates the influences of three different input parameters, such as feed rate, insert nose radius, and insert coating methods, in the turning operation of Inconel 718. The coating methods were selected as medium temperature chemical vapor deposition (MT-CVD) and physical vapor deposition (PVD) and in addition to coating methods, the role of various coating materials was discussed since the inserts were coated with multi-layers of TiCN/Al 2 O 3 /TiN and single-layer of TiAlN on carbide substrates. The results were discussed in terms of wear behavior of cutting tools and surface quality of the workpiece, which is indicated by surface roughness. A full factorial experimental design was employed in the present work and the results were evaluated using main effects plots. Furthermore, the analysis of variance (ANOVA) method was applied to specify both reactive and non-reactive effects of experimental parameter reactions. The results showed that surface roughness is reduced using low feed rates and large nosed inserts in the operations. Furthermore, TiAlN-coated inserts with PVD method provided better surface finish than with MT-CVD method. It was also found that surface roughness increases as the wear rate of inserts increases.
Investigation of tangential force on ball nose rake face during high-speed milling of Inconel 718
Notch wear and flaking are common tool damage found during end milling. The problems are caused by abrasive wear and excessive cyclic load exerted on cutting tool. This study presents an experimental investigation on the effect of various cutting parameters in highspeed machining of aged Inconel 718 on the tangential force. The effect of cutting speed, feed rate, depth of cut and width of cut on cutting forces had been studied. The cutting parameters were cutting speed, Vc of 100-140 m/min, feed rate, fz of 0.1-0.2 mm/tooth, depth of cut, ap of 0.5-1.0 mm and width of cut, ae of 0.2-1.8 mm. The results show that the width of cut is the main factor in controlling tangential force during end milling, followed by depth of cut and feed rate. These factors controlling the volume of material removed so that larger stress created on the cutter rake face.
INVESTIGATION OF SURFACE ROUGHNESS IN MILLING OF AA8011 USING SOLID CARBIDE END MILL TOOL
IAEME PUBLICATION, 2024
This study used AA8011 High Speed Milling and Solid Carbide End Mill cutting tools to examine the influence of several cutting parameters, namely cutting speed, feed rate, and depth of cut, on the ultimate performance attributes, specifically surface roughness. An analysis will be conducted using Taguchi's L9 orthogonal array and ANOVA to examine the collective effects of the process parameter on two presentation features. The data suggest that feed rate and cutting speed may effectively manage surface roughness. Nevertheless, the depth of cut is the paramount factor in determining the feed rate. The empirical data was then subjected to multiple linear regression analysis in order to ascertain the allowable range of surface roughness and establish a correlation between cutting parameters and performance characteristics. The examination of the machined surface of the tool workpiece was conducted using both an optical microscope and a scanning electron microscope (SEM), while adhering to optimal cutting conditions (vs = 450 m/min, ft = 0.1 mm/rev, and dc = 0.25 mm
A Study on the Effects of Milling Strategy on Surface Roughness
In this study, DIN 1.2344 hot work steel which was hardened at 51 HRC hardness value was processed by using high-speed milling technology, and different milling parameters with 6 mm-diameter spherical endmill and the surface qualities which were obtained as a result of milling were examined. Axial and radial feed values, feed value per tooth and depth of cut were changed between the range of 0.05 and 0.1 mm and the rate of cutting was changed between the range of 485 rpm and 4,000 rpm. These millings were carried out on material in the spherical form of which diameter was 21 mm, and the central angle was 150º. Also, milling directions were processed in different ways as climb milling, conventional milling and bidirectional milling in experimental cuttings. Surface roughness was examined in directions with 15º, 45º, 75º, 90º, 105º, 135º and 165º central angles on the material which was processed. The best surface quality was achieved in regions with 15º and 45º angles.
2013
In this study, we have investigated the effects of different insert radii of cutting tools, different depths of cut and, different feed rates on the surface quality of the workpieces depending on various processing parameters. Properly, the AISI 1030 steel is processed at a digitally controlled computerised numerical control(CNC) turning lathe without using cooling water with three different insert radii (0.4, 0.8, and 1.2 mm) of cemented carbide cutting tools, coated with three layer coating materials (outermost is TiN) applied by the chemical vapour deposition CVD technique. The effects of five different depths of cut (0.5, 1, 1.5, 2, 2.5 mm) and five different feed rates/advancing steps (0.15, 0.2, 0.25, 0.30, 0.35 mm/rev) on the surface roughness values have been investigated by a turning process while from the cutting parameters the cutting speed is kept constant at (300 m/min). It is seen that the insert radius, feed rate, and depth of cut have different effects on the surface roughness. In the experiments, the minimum average surface roughness has been obtained using the cutting tools of maximum insert radius (1.2 mm). The surface roughness have been improved by 293% when the insert radius (0.4 mm) was increased by 200% (1.2 mm). When the feed rate (0.35 mm/rev) was reduced by 133% (0.15 mm/rev), the surface roughness have been improved by 313%, and by reducing the depth of cut (0.5 mm) by 400% (0.25 mm), an amelioration of 23% has been obtained on the surface roughness.