Key improvements in the machining of difficult-to-cut aerospace superalloys

Ezugwu, E. O.

doi:10.1016/j.ijmachtools.2005.02.003

Cited by 767 publications

(294 citation statements)

References 25 publications

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“…Concerns about fabrication difficulty have increased, e.g., the processing of difficult-to-cut material [83] or bio-material [84]. It was once thought impossible to use conventional manufacturing techniques; however, researchers have investigated solutions to the problems involved, typically using hybrid manufacturing processes [85].…”

Section: Same Scale In Width and Heightmentioning

confidence: 99%

Hybrid 3D printing by bridging micro/nano processes

Yoon

Jang

Kim

et al. 2017

J. Micromech. Microeng.

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The aim of this work was to develop a novel hybrid manufacturing method for nanoscale three-dimensional (3D) printing with multi-material capabilities. 3D structuring methods at the micro/nanoscale are major goals of various engineering fields, and much work has been carried out to improve the minimum feature size, geometrical complexity, and material selection. With the aim of nanoscale multimaterial printing, a hybrid process was reported with an integrated nanoparticle deposition system (NPDS) and focused ion beam (FIB) system; however this process has limitations in terms of surface roughness and control over the layer thickness, as well as with the process scale, and furthermore, lack of sacrificial layers.In this dissertation, a novel hybrid process is described, which combines aerodynamically focused nanoparticle (AFN) printing, micro-machining and focused ion beam (FIB) milling. AFN printing is based on NPDS, and micromachining was used for local planarization. In addition to these processes, spincoating was used to fabricate sacrificial layers. By bridging these different II micro/nanoscale processes, the resulting hybrid process can address the limitations of the individual processes.To create the hybrid process, each process was investigated to enable compatibility. With the AFN printing system, the surface morphology of a detached substrate was observed, and the bonding mechanism between the substrate and nanoparticles was investigated. A novel printing strategy was identified to reduce the scale of the process. With the micro-machining system, different tool geometries were investigated. Complex geometries inspired by conventional-scale tools were implemented on the micro-scale, and their effects were investigated. With the FIB system, material re-deposition phenomena were investigated to reduce defects that occur during ion sputtering. A novel path-generation strategy was identified and investigated for different scanning paths.Process capability is discussed using fabrication examples and functional applications. The novel hybrid process represents a significant advance in the state of the art, and enables far improved process scales or dimensional degree of freedom, without losing the advantages of broad choice of materials.3D-pinted micro bi-material cantilevers were fabricated as a thermal actuator.The mechanical and thermal properties of the structure were investigated using an in-situ measurement system, and irregular thermal phenomena were analyzed. It is expected that these in-situ measurements of the 3D printed microstructure will contribute to materials research.Various 3D structures can be fabricated using the process described here from a range of metal/ceramic inorganic materials, including polymers. In particular, it is expected that the process will contribute to the area of customized nanoscale structuring, with potential applications in medical treatments. It is also expected that this work will contribute to further improvements in manufacturing technology by combining different m...

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Section: Same Scale In Width and Heightmentioning

confidence: 99%

Hybrid 3D printing by bridging micro/nano processes

Yoon

Jang

Kim

et al. 2017

J. Micromech. Microeng.

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“…Wynika to głównie z prostego tłumaczenia naukowych publikacji, opisów patentowych i opracowań wdrożenio-wych. Przykładowo, w języku rosyjskim pojęcia te brzmią: ротационное резание, ротационное инструменты, a w języku angielskim: rotary tools (RT), rotary cutting [4][5][6]. Najbardziej popularna grupa narzędzi z ostrzami obrotowymi to narzędzia tokarskie, tradycyjnie realizujące ruch posuwowy, nieobrotowy (tabl.…”

Section: Narzędzia Obrotowe Czy Narzędzia Z Ostrzami Obrotowymi?unclassified

“…Zaproponowano więc, jako efekt badań własnych [1,2], studium literatury przedmiotu i patentów [3][4][5][6][7][8][9] oraz wprowadzenie systematyki w dziedzinie konstrukcji tych narzędzi i ich zastosowań. Wydaje się to uzasadnione również w kontekście ich historycznego rozwoju.…”

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Tools with rotary cutting edges – classification and terminology

Cieloszyk

Fabisiak

2017

Mechanik

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Na tle stanu wiedzy, analizy literatury i własnych doświadczeń w badaniach narzędzi z ostrzami obrotowymi przedstawiono stosowaną terminologię i klasyfikację tych narzędzi w procesach obróbki frezowaniem, toczeniem, rozwiercaniem i powiercaniem. Na podstawie tej analizy zaproponowano skorygowaną i ujednorodnioną terminologię i klasyfikację. SŁOWA KLUCZOWE: narzędzia z ostrzami obrotowymi, narzę-dzia z ostrzami samoobrotowymi, narzędzia z wymuszonym obrotem płytkiResearch focuses on unconventional tools with the rotary edges (RET -rotary edges tools) type self-propelled rotary edges tool (SPRET) and driven rotary edges tools (DRET). Based on the analysis, corrected terminology and classification are presented.

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“…However, the mentioned properties are responsible for poor machinability of the Inconel 718 from various points of view such as surface quality and tool wear [2][3][4]. Nickel alloy is difficult to cut due to rapid work hardening.…”

Section: Introductionmentioning

confidence: 99%

“…Nickel alloy is difficult to cut due to rapid work hardening. Much tool failure and serious tool wear in cutting of superalloy have been regarded as a challenging problem for modern traditional manufacture [2].…”

Section: Introductionmentioning

confidence: 99%

A Study on Ultrasonic Elliptical Vibration Cutting of Inconel 718

Haidong

Zou

et al. 2016

Shock and Vibration

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Inconel 718 is a kind of nickel-based alloys that are widely used in the aerospace and nuclear industry owing to their high temperature mechanical properties. Cutting of Inconel 718 in conventional cutting (CC) is a big challenge in modern industry. Few researches have been studied on cutting of Inconel 718 using single point diamond tool applying the UEVC method. This paper shows an experimental study on UEVC of Inconel 718 by using polycrystalline diamond (PCD) coated tools. Firstly, cutting tests have been carried out to study the effect of machining parameters in the UEVC in terms of surface finish and flank wear during machining of Inconel 718. The tests have clearly shown that the PCD coated tools in cutting of Inconel 718 by the UEVC have better performance at 0.1 mm depth of cut as compared to the lower 0.05 mm depth of cut and the higher 0.12 or 0.15 mm depth of cut. Secondly, like CC method, the cutting performance in UEVC increases with the decrease of the feed rate and cutting speed. The CC tests have also been carried out to compare performance of CC with UEVC method.

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Key improvements in the machining of difficult-to-cut aerospace superalloys

Cited by 767 publications

References 25 publications

Hybrid 3D printing by bridging micro/nano processes

Hybrid 3D printing by bridging micro/nano processes

Tools with rotary cutting edges – classification and terminology

A Study on Ultrasonic Elliptical Vibration Cutting of Inconel 718

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