Machinability improvement in Inconel-718 by enhanced tribological and thermal environment using textured tool

Darshan, Chetan; Jain, Sumit; Dogra, Manu; Gupta, Munish Kumar; Mia, Mozammel

doi:10.1007/s10973-019-08121-y

Cited by 41 publications

(13 citation statements)

References 35 publications

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“…The tool–chip contact form of Tool 1 was full contact, whereas that of Tool 2 was not full contact, as shown in Figure 4 a,b. Based on our previous research [ 28 ], the force-balance relationships in Figure 4 c,d for the two tools are given as:

where,

and

are the main and radial cutting forces,

is friction angle, and

is rake angle, respectively. From Figure 4 c,d, it can be concluded that

, as both tools are used under equivalent situations during the turning of Inconel 718.…”

Section: Resultsmentioning

confidence: 99%

“…The microtextures enhanced the internal cooling abilities, and, thus, the cutting force was reduced and the adhesive resistance and abrasive wear resistance of the material improved. Darshan et al [ 28 ] pointed out that the microchannel textured inserts played the role of chip breaker, which decreased the contact length between the tool and chip, paving the way for a more rational chip shape. The microchannel texture achieved certain functional tasks, which were to decrease the chip curvature radius, plastically deform the chips, and break chips into short pieces.…”

Section: Introductionmentioning

confidence: 99%

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Influence of Microgroove Structure on Cutting Performance and Chip Morphology during the Turning of Superalloy Inconel 718

et al. 2021

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This study designed a new microgroove cutting tool to machine Inconel 718 and focused on the effect of microgroove structure on the cutting performance and chip morphology during the turning. A comparative analysis of the cutting force, cutting temperature, tool life, tool wear, and chip morphology of the microgroove cutting tool and the original cutting tool was conducted. The main cutting force and temperature of the microgroove cutting tool were reduced by 12% and 12.17%, respectively, compared with the original cutting tool. The microgroove cutting tool exhibited a significant improvement compared with the original cutting tool, which extended the tool life by up to 23.08%. Further, the microgroove cutting tool distorted the curl radius of the chips extensively. The experimental results showed that the microgroove structure can not only improve the tool life, but also improve the chip breaking effect.

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where,

and

are the main and radial cutting forces,

is friction angle, and

is rake angle, respectively. From Figure 4 c,d, it can be concluded that

, as both tools are used under equivalent situations during the turning of Inconel 718.…”

Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Influence of Microgroove Structure on Cutting Performance and Chip Morphology during the Turning of Superalloy Inconel 718

et al. 2021

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“…Surface burning leads to poor surface quality, and chemical reactivity accelerating the tool wear as reported by numerous researchers [2][3][4]. To cope up with the challenge, it is necessary to use low cutting conditions to achieve better surface quality, low temperature, and gradual tool wear.…”

Section: Introductionmentioning

confidence: 99%

Tribological and Machinability Performance of Hybrid Al2O3 -MWCNTs MQL for Milling Ti-6Al-4V

Jamil¹,

He²,

Zhao³

et al. 2021

Preprint

Self Cite

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Recent burgeoning development in nanotechnology unfold an avenue in the manufacturing industry. Owing to the superior heat transfer potential of nanoadditives mentioned recently, it could be interesting to improve the heat transfer and tribological capability of metal cutting fluids by mixing nanofluids in emulsions properly. In order to attain high-performance cutting of difficult-to-cut alloys, hybrid nanofluids assisted Minimum Quantity Lubrication (MQL) system is applied with the anticipation of efficient lubrication and heat transfer. Taguchi based L16(43) orthogonal array is used involving nanofluids concentrations of alumina-multiwalled carbon nanotubes (Al2O3-MWCNTs) air pressure and cooling flow rate at constant cutting conditions in the milling of Ti-6Al-4V. The resultant cutting force (FR), cutting temperature (T), and surface roughness (Ra) is considered as key machining responses. Besides, tool wear, chip analysis, and surface topography are also analyzed under the effect of hybrid nanofluids. Findings have shown the minimum resultant force, cutting temperature and surface roughness of 24.3N, 148.7oC, and 0.67µm respectively at nanofluids concentration of 0.24vol%, 120ml/h of flow rate at 0.6MPa of air pressure. The microscopic analysis of the end-mill depicted minor thermal damage, chip-welding, and coating peeling. Also, chip analysis depicts the clean back surface and less melting of saw-tooth chip edges. The surface topography confirms the less micro-adhesion of chips and material debris. The summary showed that appropriately chosen MQL parameters have improved the lubrication/cooling performance by providing oil film and enhancing the milling performance measures. The outcomes of the proposed study are useful for the manufacturing industry for the enhancement of process performance.

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“…Darshan studied the improvement of tribology and thermal environment of inconel-718 alloy by textured tools. The results reveal that the textured tools perform better, ensuring lower tool wear (VB), reduced cutting forces (Fc), lower surface roughness (Ra) and acceptable chip form [23,24].…”

Section: Introductionmentioning

confidence: 99%

Optimization of Texture Density Distribution of Carbide Alloy Micro-Textured Ball-End Milling Cutter Based on Stress Field

Zheng

Yang

2020

Applied Sciences

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The insertion of micro-textures plays a role in reducing friction and increasing wear resistance of the cutters, which also has a certain impact on the stress field of the cutter during milling. Therefore, in order to study the mechanisms of friction reduction and wear resistance of micro-textured cutters in high speed cutting of titanium alloys, the dynamic characteristics of the instantaneous stress field during the machining of titanium alloys with micro-textured cutters were studied by changing the distribution density of the micro-textures on the cutter. First, the micro-texture insertion area of the ball-end milling cutter was theoretically analyzed. Then, variable density micro-textured ball-end milling cutters and non-texture cutters were used to cut titanium alloy, and the mathematical model of milling force and cutter-chip contact area was established. Then, the stress density functions of different micro-texture density cutters and non-texture cutters were established to simulate the stress fields of variable density micro-textured ball-end milling cutters and non-texture cutters. Finally, the genetic algorithm was used to optimize the variable density distribution of micro-textured cutters in which the instantaneous stress field of the cutters was taken as the optimization objective. The optimal solution for the variable density distribution of the micro-textured cutter in the cutter-chip tight contact area was obtained as follows: the texture distribution densities in the first, second, and third areas are second, and third areas are 0.0905, 0.0712, and 0.0493, respectively.

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Machinability improvement in Inconel-718 by enhanced tribological and thermal environment using textured tool

Cited by 41 publications

References 35 publications

Influence of Microgroove Structure on Cutting Performance and Chip Morphology during the Turning of Superalloy Inconel 718

Influence of Microgroove Structure on Cutting Performance and Chip Morphology during the Turning of Superalloy Inconel 718

Tribological and Machinability Performance of Hybrid Al2O3 -MWCNTs MQL for Milling Ti-6Al-4V

Optimization of Texture Density Distribution of Carbide Alloy Micro-Textured Ball-End Milling Cutter Based on Stress Field

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