Multi-Objective Optimization Using Box-Behken of Response Surface Methodology for High-Speed Machining of Inconel 718

Abstract

This study was carried out to investigate how the high-speed milling of Inconel 718 using ball nose end mill could enhance the productivity and quality of the finish parts. The experimental work was carried out through Response Surface Methodology via Box-Behnken design. The effect of prominent milling parameters, namely cutting speed, feed rate, depth of cut (DOC), and width of cut (WOC) were studied to evaluate their effects on tool life, surface roughness and cutting force. In this study, the cutting speed, feed rate, DOC, and WOC were in the range of 100 - 140 m/min, 0.1 - 0.2 mm/tooth, 0.5 - 1.0 mm and 0.2 - 1.8 mm, respectively. In order to reduce the effect of heat generated during the high speed milling operation, minimum quantity lubrication of 50 ml/hr was used. The effect of input factors on the responds was identified by mean of ANOVA. The response of tool life, surface roughness and cutting force together with calculated material removal rate were then simultaneously optimized and further described by perturbation graph. Interaction between WOC with other factors was found to be the most dominating factor of all responds. The optimum cutting parameter which obtained the longest tool life of 60 mins, minimum surface roughness of 0.262 μm and resultant force of 221 N was at cutting speed of 100 m/min, feed rate of 0.15 mm/tooth, DOC 0.5 m and WOC 0.66 mm.

Ceramic Cutting Materials and Tools Suitable for Machining High-Temperature Nickel-Based Alloys: A Review

“…The author also noted a serrated morphology shaving, indicating that thermal deformation during the cutting process. Li et al [167] determined in their work the optimal cutting speed when processing Inconel 718, at which there are no diffusion phenomena that contribute to the formation of cuts on the back surface and craters on the front surface. Nalbant et al [168] studied the wear mechanisms of SiAlON tools when machining a nickel alloy with plates having different geometric shapes (RNGN 120700, and SNGN 120712).…”

Machinability of Rene 65 Superalloy

“…The Box Behnken-based response surface method (RSM) offers the advantage of assessing a number of mid-range points in its design. This RSM method has been applied in the ultra-high precision machining of contact lenses [21] and in other machining techniques [22]. This methodology is best-suited for experimental tests with limitations on extreme ranges.…”