Cryogenic Treatment of Nimonic Alloy- Hard Turning: State -of-the-art, Challenges and Future Directions

Proceedings of the Institution of Mechanical Engineers, Part B:

2021

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Nimonic C-263 is predominantly used in the manufacturing of heat susceptible intricate components in the gas turbine, aircraft, and automotive industries. Owing to its high strength, poor thermal conductivity, the superalloy is difficult to machine and causes rapid tool wear during conventional machining mode. Moreover, the unpleasant machining noise produced during machining severely disrupts the tool engineer’s concentration, thereby denying a precise and environment friendly machining operation. Hence, close dimensional accuracy, superior machined surface quality along with production economy, and pleasant work environment for the tool engineers is the need of an hour of the current manufacturing industry. To counter such issues, the present work attempts to compare and explore the machinability of two of the most popular machining strategies like minimum quantity lubrication (MQL) and cryogenic machining process during turning of Nimonic C-263 work piece in order to achieve an ideal machining environment. The machining characteristics are compared in terms of surface roughness (SR), power consumption (P), machining noise (S), nose wear (NW), and cutting forces (CF) to evaluate the impact of machining variables like cutting speed (Vc), feed (f), and depth of cut (ap) with a detailed parametric study and technical justification. Yet again, an investigation is conducted to compare both the machining strategies in terms of qualitative responses like chip morphology, total machining cost, and carbon emissions. The study revealed that cryogenic machining strategy is adequately proficient over MQL machining to deliver energy proficient and gratifying work environment for the tool engineers by reducing the cost of machining and improving their work efficiency.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…21–23 Recently, numerous studies reported the adoption of cryogenic treatment to attain the enhanced machined surface and flank wear reduction during the turning process. 6,13,24,25…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Performance assessment of energy efficient and eco-friendly turning of Nimonic C-263: A comparative study on MQL and cryogenic machining

Proceedings of the Institution of Mechanical Engineers, Part B:

2021

Self Cite

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“…The use of this superalloy is frequently seen in steam turbines and internal combustion (IC) engines. Various grades of alloys on the basis of their composition like Nimonic 75, 80A, 90, 110,105, 115, 263 (Patel, 2006;Jadhav et al 2019).…”

Section: Introductionmentioning

confidence: 99%

Comparative analysis of indirect, direct and hybrid cryogenic machining of Nimonic C-263 superalloy

JER is an international, peer-reviewed journal that publishes f

2021

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 superalloy with a multilayer CVD insert. Taguchi’s L-27 orthogonal array is used plan the experiments. Effects of input parameters viz. cutting speed (V), cutting feed (F), depth of cut (D) are studied on responses viz. surface roughness (SR), nose wear (NW) and cutting forces (CF) under indirect, direct and hybrid cryogenic (indirect+direct) 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 grey relational analysis (TGRA). Feed rate (F) is found to be the most influential parameter from the analysis of variance (ANOVA) of grey relational grade (GRG). Further, the means of GRG for each level of process parameters are used to improve the optimal process parameters. Finally, a confirmative experiment is performed on the optimum machining conditions to validate the optimization study results. It is seen that the value of GRG is improved by 9.34% when compared to the previous best result. The proposed work can be beneficial to choose ideal process conditions to enhance the performance of turning operation.

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Numerical investigation and experimental validation of the effects on response parameters in a cryogenic assisted turning of Nimonic C-263 alloy

Int J Interact Des Manuf

Magdum

2023