Effect of Cryogenic Grinding on Fatigue Life of Additively Manufactured Maraging Steel

Balan, A.S.S.; Chidambaram, K.; Kumar, Arun; Hariharan, K.; Pimenov, Danil Yurievich; Giasin, Khaled; Nadolny, Krzysztof

doi:10.3390/ma14051245

Cited by 19 publications

(7 citation statements)

References 40 publications

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“…The grinding temperature is not directly correlated with the surface finish of the workpiece. According to literature, as the temperature rises, the surface finish decreases because of decrease in hardness and increase in oxidation of the grinded surface [30]. Therefore, superior surface finish is obtained at lower grinding temperatures.…”

Section: Surface Roughness Of Finished Am and Conventional Samples In...mentioning

confidence: 99%

“…Cryogenic grinding effectively cooled the workpiece, bringing the temperature down and hardening the materials. The liquid nitrogen spray that creates the cold grinding zone in the cryogenic condition enhances the material's microhardness [18,30]. In addition, it is important to keep in mind that when finishing AM samples, the optimized input parameters for a conventional material might have a substantial impact on the surface quality.…”

Section: Microhardness Of Finished Am and Conventional Samples Under ...mentioning

confidence: 99%

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Surface Integrity of Cryogenically Finished Additively Manufactured and Conventional Ti-6Al-4V Alloy

Singh

Kumar

Jain

2023

Metals

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Additive manufacturing (AM) is used for the fabrication of solid components of complex geometries for customized applications. However, AM-fabricated components frequently require finishing operations such as abrasive grinding, which causes a different surface characteristic compared to the conventionally manufactured components. Thus, it is essential to study the effect of process parameters and the heat treatment on surface quality of the AM components because these may behave differently to the conventional manufactured components. In this study, surface characteristics of AM samples of Ti-6Al-4V with a cryogenically cooled finishing operation is compared with that of conventionally processed samples. The samples under investigation were fabricated by two different methods, namely, Direct Metal Laser Sintering (DMLS) and conventional processing. The effect of the two processes on surface characteristics, such as microhardness, surface roughness, X-ray diffraction (XRD), and mechanical properties has been studied. The average surface roughness from cryogenic grinding was reduced by 27.25% and 23.15% for the AM, and 30.08% and 29.13% for conventional samples, as compared to dry and moist conditions, respectively. The finished DMLS and conventional samples showed increase of microhardness by 14.07%, 14.27%, 17.54% and 17.48%, 8.06%, 38.68%, in dry, moist, and cryogenic conditions, respectively. In cryogenic conditions, as the DOC and table feed increased, a greater increase in peak broadening was observed. The peak broadening in XRD of finished DMLS components indicates that a significant level of plastic deformation occurred compared to the finished conventionally manufactured Ti-6Al-4V samples, which suggests that the DMLS samples are more sensitive to the finishing process. Compared to dry and moist grinding, cryogenic grinding was found to have the smallest grains in the layer just below the surface. The impact of cryogenic cooling on surface properties of AM Ti-6Al-4V samples is higher as compared to that on conventionally processed Ti-6Al-4V samples.

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Section: Surface Roughness Of Finished Am and Conventional Samples In...mentioning

confidence: 99%

Section: Microhardness Of Finished Am and Conventional Samples Under ...mentioning

confidence: 99%

Surface Integrity of Cryogenically Finished Additively Manufactured and Conventional Ti-6Al-4V Alloy

Singh

Kumar

Jain

2023

Metals

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“…An alternative is to use a non-water-based or oil-based coolant such as liquid nitrogen and carbon dioxide which are also known as cryogenic coolants. The use of cryogenic coolants was mainly proposed for machining hard to cut materials such as titanium and steel alloys [7][8][9]. Cryogenic coolants are environmentally friendly, providing a clean machining process without the need to dispose or handle the coolant waste [10].…”

Section: Introductionmentioning

confidence: 99%

The effect of cryogenic machining of S2 glass fibre composite on the hole form and dimensional tolerances

Köklü

Morkavuk

Featherston

et al. 2021

Int J Adv Manuf Technol

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S2 glass fibre reinforced epoxy composites are widely used in aeronautical applications owing to their excellent strength to weight ratio. Drilling glass fibres can be cumbersome due to their abrasive nature and poor thermal conductivity. Moreover, the use of conventional coolants is not desirable due to contamination and additional costs for cleaning the machine part. An alternative is to use environmentally friendly coolants such as liquid nitrogen (LN2) which have been previously employed in machining metals and composites. The current study investigates the effect of drilling S2 glass fibre composite in a bath of LN2. The study aims to evaluate the effect of spindle speed, feed rate and the presence of cryogenic cooling on the form and dimensional tolerances of the hole (hole size, circularity, cylindricity and perpendicularity). Design of experiments and analysis of variance (ANOVA) were used to determine the contribution of the input parameters on the analysed hole quality metrics. Results indicated that drilling S2 glass fibre in a cryogenic bath increased hole size significantly beyond the nominal hole diameter. The hole circularity and cylindricity were reduced compared to holes drilled under dry condition under all cutting parameters due to enhanced thermal stability during the drilling process. The current study aims to provide the scientific and industrial communities with the necessary knowledge on whether cryogenic bath cooling strategy provides better hole quality output compared to dry drilling and other cryogenic cooling strategies which were previously reported in the open literature.

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“…The experimental results showed that Ra could be reduced around 87% compared cryogenic condition to dry grinding. 18 Another type of CHT was performed by shallow and deep methods. Arun et al examined the cutting tools, applied to deep and shallow CHT to obtain thrust force, Ra and exit burry height and circularity error when 304 austenitic stainless steel was drilled.…”

Section: Introductionmentioning

confidence: 99%

Comparative investigations of cryo-treated and untreated inserts on machinability of AISI 1050 by using response surface methodology, ANOVA and Taguchi design

Baday

Ersöz

2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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This study aims to focus on the machinability of the AISI 1050 workpieces with cutting inserts, treated under deep cryogenic heat (−146 °C), and with untreated ones, and to investigate the optimization of cutting parameters and heat treatment conditions for surface roughness and cutting force by using Taguchi mixed design and Response Surface Methodology (RSM). The machining experiment was performed on a CNC lathe with machining parameters such as three feed rates, three cutting speeds and a constant depth of cut under dry condition and with heat treatment condition. As is known, Taguchi design L18 (32 21) consists of three factors; cutting parameters with each one of three levels and heat treatment condition with two levels. The results of machining tests were evaluated considering surface roughness, vibrations and cutting force. Furthermore, chip morphology and wear led by cryo-treated and untreated inserts were detected with the aid of a scanning electron microscope. The results demonstrated that cryo-treated (CTI) insert had lower tool wear, vibration, and cutting force than untreated insert (UI) in all conditions. In aspect of chip morphology, untreated inserts had bigger and larger serrations than the treated inserts. In addition, according to Taguchi S/N ratio, optimal cutting parameters and heat treatment conditions were obtained from CHT1, V3, and f1 for the Fc and from CHT1, V1, and f1 for the Ra, respectively. Also, the most significant control factors on surface roughness and cutting force were feed rate depending on ANOVA results and RSM. Validation test results demonstrated that RSM and Taguchi mixed design calculated the cutting force (R2RSM (CTI and UI) = 99.99% and R2Tag. = 99.95%) and surface roughness (R2RSM (CTI) = 99.76%, R2RSM (UI) = 99.59% and R2Tag. = 99.12%). Therefore, RSM and Taguchi mixed design predicts highly well match experimental data with prediction data.

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Effect of Cryogenic Grinding on Fatigue Life of Additively Manufactured Maraging Steel

Cited by 19 publications

References 40 publications

Surface Integrity of Cryogenically Finished Additively Manufactured and Conventional Ti-6Al-4V Alloy

Surface Integrity of Cryogenically Finished Additively Manufactured and Conventional Ti-6Al-4V Alloy

The effect of cryogenic machining of S2 glass fibre composite on the hole form and dimensional tolerances

Comparative investigations of cryo-treated and untreated inserts on machinability of AISI 1050 by using response surface methodology, ANOVA and Taguchi design

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