An experimental investigations on effects of cooling/lubrication conditions in micro milling of additively manufactured Inconel 718

Danish, Mohd; Aslantaş, Kubilay; Hasçelik, Ahmet; Rubaiee, Saeed; Gupta, Munish Kumar; Yildirim, Mehmet Bayram; Ahmed, Anas; Mahfous, Abdullah

doi:10.1016/j.triboint.2022.107620

Cited by 34 publications

(2 citation statements)

References 44 publications

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“…For s = 50 m/min, VB = 110 μm was reached and elapsed Δt = 14 min. Danish et al [ 95 ] studied micro-milling on AMed INCONEL ® 718 under different sustainable cooling conditions. TW, R a and burrs generated during micro-milling experiments were examined ( Figure 20 ) under the influence of air, minimum quantity lubrication (MQL) and emulsion flood-cooling (EFC) conditions.…”

Section: Literature Reviewmentioning

confidence: 99%

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An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

Pedroso,

Sebbe,

Silva

et al. 2024

Materials

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Build-up-edge (BUE), high-temperature machining and tool wear (TW) are some of the problems associated with difficult-to-machine materials for high-temperature applications, contributing significantly to high-cost manufacturing and poor tool life (TL) management. A detailed review of non-traditional machining processes that ease the machinability of INCONEL®, decrease manufacturing costs and suppress assembly complications is thus of paramount significance. Progress taken within the field of INCONEL® non-conventional processes from 2016 to 2023, the most recent solutions found in the industry, and the prospects from researchers have been analysed and presented. In ensuing research, it was quickly noticeable that some techniques are yet to be intensely exploited. Non-conventional INCONEL® machining processes have characteristics that can effectively increase the mechanical properties of the produced components without tool-workpiece contact, posing significant advantages over traditional manufacturing.

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Section: Literature Reviewmentioning

confidence: 99%

“… ( a ) Evaluation of surface roughness (SR) in micro slots. ( b ) Measurement of burr width at slot edges [ 95 ]. …”

Section: Figurementioning

confidence: 99%

An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

Pedroso,

Sebbe,

Silva

et al. 2024

Materials

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Influence of the parameters of a minimum quantity lubrication system on micro milling process results

Kieren-Ehses¹,

Mayer²,

Kirsch³

et al. 2023

Int J Adv Manuf Technol

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Micro end mills are characterized by high abrasive wear. To counteract this high abrasive wear, metalworking fluids can be applied. There are various methods to supply these fluids. One of these methods is the minimum quantity lubrication (MQL). The objective of this research is to investigate the influence of the supply direction and air pressure of a MQL system on the process result when micro milling. Micro milling tests were carried out using micro end mills made of cemented carbide with an effective diameter of 50 $$\upmu \text {m}$$ μ m . When machining commercially pure titanium, the supply direction was varied at four levels relative to the feed direction (0$${}^{\circ }$$ ∘ , 90$${}^{\circ }$$ ∘ , 180$${}^{\circ }$$ ∘ and 270$${}^{\circ }$$ ∘ ) and the air pressure at three levels (0.1 MPa, 0.2 MPa and 0.3 MPa). At each air pressure, the spindle speed was varied at three levels (30,000 rpm, 60,000 rpm, 120,000 rpm). Tool wear, surface quality, burr formation, and manufacturing accuracy were analyzed. In terms of the supply direction, the best results were obtained with a supply direction of 180$${}^{\circ }$$ ∘ (in feed direction) — the lowest roughness and the most uniform slot bottom structure were machined. Regarding the influence of the supply direction on tool wear and manufacturing accuracy, no significant differences could be found. With regard to the air pressure, no clear result could be achieved. The influence of the spindle speed on the process results was higher than the influence of the air pressure. However, it is possible to select a suitable air pressure depending on the spindle speed.

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Surface roughness optimization of hybrid PBF-LB/M-built Inconel 718 using in situ high-speed milling

Sommer,

Hornung,

Esen

et al. 2024

Int J Adv Manuf Technol

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We report on the optimization of the surface roughness of hybrid additive manufactured Ni superalloys, combining a conventional laser powder bed fusion process with in situ high-speed milling. This remarkable hybrid approach has only recently been applied to different steel types and barely to Ni superalloys which opposite to steel appear to be challenging for milling processes, particularly within the powderbed of laser powder bed fusion. Different influencing factors on the surface roughness are varied in this study, following the Taguchi method. Their effect is evaluated with respect to the average surface roughness and the maximum surface roughness. The signal-to-noise ratio for the varied parameters infeed, z-pitch, feed rate, and spindle speed is calculated, determining their relevance on the surface roughness, and defining an optimal parameter combination. As the surface quality is optimized to $$\varvec{R_a=0.47\, \mu m}$$ R a = 0.47 μ m , the definition of the optimal parameter combination is of the highest relevance for the application of this novel manufacturing approach for Inconel. Using linear regression, the resulting surface roughness of these parameters is predicted, getting validated by the experimental evaluation. Due to a further analysis, including EDX analysis and a quantitative element analysis at different positions of the flank of the milling cutter, wear characteristics as well as the dissipation of the coating of the milling cutter are detected. The flank wear and the resulting breakage of the cutting edge are defined as the main reasons of a rising surface roughness.

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An experimental investigations on effects of cooling/lubrication conditions in micro milling of additively manufactured Inconel 718

Cited by 34 publications

References 44 publications

An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

An In-Depth Exploration of Unconventional Machining Techniques for INCONEL® Alloys

Influence of the parameters of a minimum quantity lubrication system on micro milling process results

Surface roughness optimization of hybrid PBF-LB/M-built Inconel 718 using in situ high-speed milling

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