Machining Parameter Optimization in High-Speed Milling for Inconel 718 Curved Surface

Ma, Jian-wei; Wang, Fuji; Zhang, Jia; Gao, Yuanyuan

doi:10.1080/10426914.2015.1117623

Cited by 14 publications

(5 citation statements)

References 20 publications

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“…Nowadays, a great opportunity has arisen to produce robust parts for aerospace and the turbine sector with advanced performances (high mechanical strength at elevated temperatures and high resistance against corrosion) made of nickel-based superalloys (e.g., Inconel-800) [1] and titanium-based superalloys (e.g., Ti-6Al-4V) [2]. However, during machining processes, they raise challenges because of high toughness, low heat transfer coefficient, and very poor work hardening [3]. These later features obstruct the efficiency and generate moderate surface quality; in addition, they bring down the manufacturing time and increase cost.…”

Section: Introductionmentioning

confidence: 99%

Parametric optimization and process capability analysis for machining of nickel-based superalloy

Gupta

Mia

Pruncu

et al. 2019

Int J Adv Manuf Technol

105

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The manufacturing of parts from nickel-based superalloy, such as Inconel-800 alloy, represents a challenging task for industrial sites. Their performances can be enhanced by using a smart cutting fluid approach considered a sustainable alternative. Further, to innovate the cooling strategy, the researchers proposed an improved strategy based on the minimum quantity lubrication (MQL). It has an advantage over flood cooling because it allows better control of its parameters (i.e., compressed air, cutting fluid). In this study, the machinability of superalloy Inconel-800 has been investigated by performing different turning tests under MQL conditions, where no previous data are available. To reduce the numerous numbers of tests, a target objective was applied. This was used in combination with the response surface methodology (RSM) while assuming the cutting force input (F c), potential of tool wear (VB max), surface roughness (Ra), and the length of tool-chip contact (L) as responses. Thereafter, the analysis of variance (ANOVA) strategy was embedded to detect the significance of the proposed model and to understand the influence of each process parameter. To optimize other input parameters (i.e., cutting speed of machining, feed rate, and the side cutting edge angle (cutting tool angle)), two advanced optimization algorithms were introduced (i.e., particle swarm optimization (PSO) along with the teaching learning-based optimization (TLBO) approach). Both algorithms proved to be highly effective for predicting the machining responses, with the PSO being concluded as the best amongst the two. Also, a comparison amongst the cooling methods was made, and MQL was found to be a better cooling technique when compared to the dry and the flood cooling.

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Section: Introductionmentioning

confidence: 99%

Parametric optimization and process capability analysis for machining of nickel-based superalloy

Gupta

Mia

Pruncu

et al. 2019

Int J Adv Manuf Technol

105

View full text Add to dashboard Cite

show abstract

“…However, the agglomeration tendency of the small powders significantly restricts the flowability of the powders [25]. Although large size (2) Hump area…”

Section: Effect Of Materials Powdersmentioning

confidence: 99%

“…It can be also applied to aerospace engines and supersonic aircraft [1]. However, Inconel 738LC is a representative of difficult-to-machine material on account of its low thermal conductivity and high reactivity with milling tools [2]. For Inconel 738LC or other difficult-tomachine materials, selective laser melting (SLM) technology shows unique advantages as a newly emerging manufacturing technology.…”

Section: Introductionmentioning

confidence: 99%

Surface Integrity of Inconel 738LC Parts Manufactured by Selective Laser Melting Followed by High-speed Milling

Ren

Guo

Zhang

2023

Chin. J. Mech. Eng.

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This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting (SLM) followed by high-speed milling (HSM). In the investigation process of surface integrity, the study employs ultra-depth three-dimensional microscopy, laser scanning confocal microscopy, scanning electron microscopy, electron backscatter diffractometry, and energy dispersive spectroscopy to characterize the evolution of material microstructure, work hardening, residual stress coupling, and anisotropic effect of the building direction on surface integrity of the samples. The results show that SLM/HSM hybrid manufacturing can be an effective method to obtain better surface quality with a thinner machining metamorphic layer. High-speed machining is adopted to reduce cutting force and suppress machining heat, which is an effective way to produce better surface mechanical properties during the SLM/HSM hybrid manufacturing process. In general, high-speed milling of the SLM-built Inconel 738LC samples offers better surface integrity, compared to simplex additive manufacturing or casting.

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“…After decades of development, the modeling technology of the curved surface has been relatively mature. However, because of its high requirements in precision and the difficulty in mathematical expressions, the curved surface machining has always been a major problem in the world today [3,4]. Polishing is essential for the traditional bathroom parts, shell parts in 3C industry and household kitchenware, and the key components in new industry such as blades, artificial bones, optical curved surfaces also require a final polishing process.…”

Section: Introductionmentioning

confidence: 99%

Process Planning of the Automatic Polishing of the Curved Surface Using a Five-axis Machining Tool

Zhang¹,

Chen²,

Chen³

et al. 2021

Preprint

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Curved surface parts are widely used in aerospace industry, automotive industry and other fields due to their excellent features in aerodynamics, fluid dynamics and thermodynamics. Compared with the modeling technology of the curved surface, the development of the processing technology of the curved surface is slightly behind. In order to improve the processing quality and efficiency of the curved surface, this paper independently developed a five-axis CNC polishing machine tool, and studied the pre-processing and the post-processing when machining the curved surface. Taking a metal shell of the mobile phone as an example, three different paths are planned for the flat surface and the curved surface respectively, and a method for generating the tool path is proposed. The kinematics model of the five-axis CNC machine tool is established, which is used to obtain the calculation formula of the movement amount of each axis when polishing in the flat surface and the curved surface of the metal shell. The polishing effects of the different paths about the surface quality and the polishing efficiency of the metal shell are studied through the polishing experiments, and the polishing path with the best surface quality and the highest polishing efficiency is found.

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Machining Parameter Optimization in High-Speed Milling for Inconel 718 Curved Surface

Cited by 14 publications

References 20 publications

Parametric optimization and process capability analysis for machining of nickel-based superalloy

Parametric optimization and process capability analysis for machining of nickel-based superalloy

Surface Integrity of Inconel 738LC Parts Manufactured by Selective Laser Melting Followed by High-speed Milling

Process Planning of the Automatic Polishing of the Curved Surface Using a Five-axis Machining Tool

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