Inconel 718 machining performance evaluation using indigenously developed hybrid machining facilities: experimental investigation and sustainability assessment

Khanna, Navneet; Shah, Priyanka; Agrawal, Chetan; Pušavec, Franci; Hegab, Hussien

doi:10.1007/s00170-020-04921-x

Cited by 42 publications

(9 citation statements)

References 31 publications

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“…In UAT, repeated separation of tool and work-piece reduces the friction between tool and chip; when the tool friction decreases, there is a corresponding increase in shear angle and an ultimately decrease in the chip thickness. Similar results are also shown in [46]. Moreover, this smooth and short chips produced in UAT do not stick to the work-piece material and hence reduced the surface roughness value.…”

Section: Chip Formation Analysis In Uat and Ct Processessupporting

confidence: 84%

Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility

Airao

Khanna

Roy

et al. 2020

Int J Adv Manuf Technol

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Many techniques have been developed to improve the machinability of aeronautical materials titanium and nickel-based alloys such as ultrasonic-assisted turning, laser-assisted turning, and cryogenic-assisted turning. This collaborative scientific investigation presents the steps taken to gain insight into the phenomena of machining Nimonic 90 (a nickel-based alloy) alloy using ultrasonically assisted turning. The cutting speed, feed rate, depth of cut, and frequency are taken as input parameters and average surface roughness (R a ), power consumption (P), and chip formation are considered as output parameters. The experiments are carried out with the full factorial design. The UAT (ultrasonically assisted turning) process gives a significant improvement in average surface roughness and power consumption because of the intermittent cutting action of the cutting tool. UAT process shows a 70-80% reduction in average surface roughness (R a ) and a 6-15% reduction in power consumption as compared with CT (conventional turning) process. Ultrasonically assisted turning also resulted in the thin and smoother chips as compared with CT process which helps to achieve a more superior machining effect. Finite element modeling shows that the quasi-static nature of the stress induced in the UAT process leads to lower force and ultimately lower power generation. Moreover, a sustainability assessment model is implemented to investigate the effect of UAT in terms of machining performance as well as sustainability effectiveness in a single integrated approach. The novelty of this work lies in providing an integrated concept that combines experimental analysis and sustainability assessment when using ultrasonic vibrational energy during turning of Nimonic 90.

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Section: Chip Formation Analysis In Uat and Ct Processessupporting

confidence: 84%

Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility

Airao

Khanna

Roy

et al. 2020

Int J Adv Manuf Technol

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“…Besides, the sustainability assessment guideline presented by [42] is used to establish the design matrix for the process assessment calculations. The sustainability indicator for the effects of the environmental metric is E ne , which denotes the amount of CO 2 emissions depending on the measured power consumption for each machining test by using a standard emission intensity standard provided in the literature [43]. The estimation of CO 2 based on power consumption during machining processes has already been used in various cases in the relevant literature [44].…”

Section: Sustainability Assessmentmentioning

confidence: 99%

Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel

Markopoulos

Karkalos

Mia

et al. 2020

Metals

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The hardened tool steel AISI O1 has increased strength, hardness, and wear resistance, which affects the complexity of the machining process. AISI O1 has also been classified as difficult to cut material hence optimum cutting parameters are required for the sustainable machining of the alloy. In this work, the effect of feed peer tooth (fz), cutting speed (vc), cutting of depth (ap) on surface roughness (Ra, Rt), cutting force (Fx, Fy), cutting power (Pc), machining cost (Ci), and carbon dioxide (Ene) were investigated during the slot milling process of AISI O1 hardened steel. A regression analysis was carried out on the obtained experimental results and the induction of nonlinear mathematical equations of surface roughness, cutting force, cutting power, and machining cost with a high coefficient of determination (R2 = 90.62–98.74%) were deduced. A sustainability assessment model is obtained for optimal and stable levels of design variables when slot milling AISI O1 tool steel. Stable indicators to ensure personal health and safety of operation, P1 values were set to “1” at a cutting speed of 20 m/min or 43.3 m/min and “2” at a cutting speed of 66.7 m/min or 90 m/min. It is revealed that for eco-benign machining of AISI O1, the optimum parameters of 0.01 mm/tooth, 20 m/min, and 0.1 mm should be adopted for feed rate, cutting speed, and depth of cut respectively.

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“…[71][72][73] Apart from Powder Mixed EDM, Hybrid EDM (H-EDM) and other hybrid machining were employed by various researchers to machined Inconel and titanium alloys. 74,75 Zhu et al 76 illuminated the working of High-Speed vibration assisted electro arc machining. It was observed that in comparison with conventional EDM, VEAM constitutes an additional electromagnetic vibration table and high-pressure pump.…”

Section: Introduction To Hybrid Processes and Powder Mixed Electrical...mentioning

confidence: 99%

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

Srivastava¹,

Vishnoi²,

Gangadhar³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Electrical discharge machining (EDM) is an exigent focus of interest for researchers since its inception. EDM has a wide range of applications due to its non-contact machining process based on the spark erosion method. EDM is a non-conventional machining process with high potential in the recent industrial era. Due to the few limitations of EDM, many hybrid techniques are evolved in recent years. The present review paper elucidates the in-depth mechanism of the material removal process in EDM. Hybrid EDM processes are also reviewed with special attention on powder mixed electrical discharge machining (PMEDM). A detailed comparison between the EDM and PMEDM is presented with a meticulous portrayal of the advancement and evolution of PMEDM. The emphasis is given on significant performance parameters, namely tool wear rate, material removal rate and surface roughness, besides other parameters. In addition, the study also includes different modelling, optimization, and surface analysis techniques on EDM. The paper concludes with the future scope of PMEDM in the fields of manufacturing along with its applications.

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Inconel 718 machining performance evaluation using indigenously developed hybrid machining facilities: experimental investigation and sustainability assessment

Cited by 42 publications

References 31 publications

Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility

Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility

Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel

An insight on Powder Mixed Electric Discharge Machining: A state of the art review

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