Effect of Machining Parameters on Surface Integrity in Machining Nimonic C-263 Super Alloy Using Whisker-Reinforced Ceramic Insert

Ezilarasan, C.; Kumar, V.S. Senthil; Velayudham, A.

doi:10.1007/s11665-012-0439-1

Cited by 66 publications

(19 citation statements)

References 19 publications

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“…Built‐up edges formation on tool had negative impact on surface finish by producing scratches along the cutter path as reported in dry machining of Nimonic‐C263 . It was also found that there is low critical feed rate beyond which surface damage increases by the larger built‐up edges formed due to the high stresses on tool edge . The dominant surface defects in dry machining were found to be scratches, chip particles, debris and feed marks; adhesion of tool material on tool face was found to be higher at low cutting speed .…”

Section: Introductionmentioning

confidence: 68%

“…The reduction in surface roughness in dry machining at v c = 50 m/min can possibly be attributed to the disappearance of built‐up edges from the tool faces, Figure , a, b. It was found previously that the formation of built‐up edges on tool faces affect surface roughness negatively as they harden on the tool face and consequently scratch the machined surface leading to the formation of long wide grooves along the cutter direction . Regardless to the suppression of adhesive wear, dry machining had adverse effect on surface quality by creating severe surface abuse as well as severe coating delamination on the tool faces.…”

Section: Resultsmentioning

confidence: 89%

“…It was also found that there is low critical feed rate beyond which surface damage increases by the larger built-up edges formed due to the high stresses on tool edge [14]. The dominant surface defects in dry machining were found to be scratches, chip particles, debris and feed marks; adhesion of tool material on tool face was found to be higher at low cutting speed [14]. Overall it was established that work hardening is the main barrier in machining Nimonic-C263 and can be avoided by careful control over the cutting parameters [13,14].…”

Section: Introductionmentioning

confidence: 98%

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Surface damages and tool wear mode in end milling of hastelloy‐C276 under dry and wet conditions

Al-Falahi¹,

Fadaeifard

Baharudin

et al. 2016

Materialwissenschaft Werkst

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Hastelloy‐C276 is a nickel based superalloy that is widely used in chemical, petro‐chemical, environmental and nuclear industries due to its outstanding performance in a wide range of corrosive mediums. The superior properties of nickel based superalloys impair their machinability which increases the difficulty in obtaining a good surface finish. Because most of the components' failures are initiated from surface defects, several researchers have been concerned about surface integrity in machining aerospace superalloys particularly Inconel‐718. Due to the lack of studies done on machining corrosion‐resistant superalloys, this study aims to investigate surface damages and tool wear modes in milling Hastelloy‐C276 under dry and wet conditions. The absence of cooling and lubricating actions in dry machining resulted in the formation of craters, severe plastic deformation, voids, debris re‐deposition and materials drag. The breakage of the nucleated carbide phases resulted in the formation of nucleated cavities on the machined surface in both wet and dry machining. Adhesive tool wear was less in dry machining due to the formation of oxide layers on tool faces which suppressed the formation of built‐up edges due to the weak adhesion properties of oxide compounds which resulted in less surface roughness at vc = 50 m/min. On the other hand, the higher temperature and friction in dry machining resulted in severer tool coating delamination.

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Section: Introductionmentioning

confidence: 68%

Section: Resultsmentioning

confidence: 89%

Section: Introductionmentioning

confidence: 98%

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Surface damages and tool wear mode in end milling of hastelloy‐C276 under dry and wet conditions

Al-Falahi¹,

Fadaeifard

Baharudin

et al. 2016

Materialwissenschaft Werkst

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“…Prasad et al [6] found that feed rate is the most significant factor affecting the surface roughness with thehelp of ANN approach. Bin Zou et al [7] studied the surface damages caused by turning NiCr20TiAl nickel based super alloy for different cutting speed, feed rate and depth of cut. It was found that, at cutting speed of 100 m/min, feed rate of 0.15 mm/rev and depth of cut of 1 mm, good surface finish is obtained with less workhardening layer, also lower cutting forces are generated.…”

Section: Introductionmentioning

confidence: 99%

Some Experimental Investigations on Turning of Nimonic 80A using Sialon Ceramic Inserts

Patil¹,

Chavan

Kadam

et al. 2017

Proceedings of the International Conference on Communication and Signal Processing 2016 (ICCASP 2016)

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Abstract:The main objective of this study is to analyze the effect of cutting speed, feed, and depth of cut on response variables such as surface roughness, tool wear, and material removal rate (MRR). Turning of NIMONIC 80A was carried out at three levels of cutting speed, feed, and depth of cut. Analysis of variance (ANOVA) is used to find which factor is significant for the output parameters. From experimental analysis it is observed that mainly major factor responsible for flank wear is cutting speed,for surface roughness is feed and to get maximum material removal rate is depth of cut. It is found from experimental results that the ceramic inserts gives better surface finish compared to carbide inserts.

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“…Similarly, Ravi and Pradeep Kumar [26] Based on literature review it has been found that most of the studies in machining with sustainable techniques are carried out on Inconel 718, Titanium alloy and various steel alloys. However, Ni-Cr-Co based Nimonic alloy is another useful engineering alloy which is widely considered for making turbine blades and various aerospace components [29]. Till now no one has attempted to understand the machining characteristics of Nimonic alloy using environment friendly sustainable techniques.…”

Section: Introductionmentioning

confidence: 99%

Environment Friendly Machining of Ni–Cr–Co Based Super Alloy using Different Sustainable Techniques

Chetan

Ghosh

Rao

2015

Materials and Manufacturing Processes

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In order to eradicate the use of mineral based cutting fluid, the machining of Ni-Cr-Co based Nimonic 90 alloy was conducted using environment friendly sustainable techniques. In this work, uncoated tungsten carbide inserts were employed for the machining under dry (untreated and cryogenically treated), MQL and cryogenic cutting modes. The influence of all these techniques was examined by considering tool wear, surface finish, chip contact length, chip thickness and chip morphology. It was found that the cryogenically treated tools outperformed the untreated tools at 40 m/min. At cutting speed of 80 m/min, MQL and direct cooling with liquid nitrogen brought down the flank wear by 50% in comparison to dry machining. Similarly at higher cutting speed MQL and cryogenic cooling techniques provided the significant improvement in terms of nose wear, crater wear area and chip thickness value. However, both dry and MQL modes outperformed the cryogenic cooling machining in terms of surface roughness value at all the cutting speeds. Overall cryo treated tools was able to provide satisfactory results at lower speed (40 m/min). Whereas both MQL and cryogenic cooling method provided the significantly improved results at higher cutting speeds (60 m/min and 80 m/min) over dry machining.

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Effect of Machining Parameters on Surface Integrity in Machining Nimonic C-263 Super Alloy Using Whisker-Reinforced Ceramic Insert

Cited by 66 publications

References 19 publications

Surface damages and tool wear mode in end milling of hastelloy‐C276 under dry and wet conditions

Surface damages and tool wear mode in end milling of hastelloy‐C276 under dry and wet conditions

Some Experimental Investigations on Turning of Nimonic 80A using Sialon Ceramic Inserts

Environment Friendly Machining of Ni–Cr–Co Based Super Alloy using Different Sustainable Techniques

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