Numerical investigation of hot ultrasonic assisted turning of aviation alloys

Sofuoğlu, Mehmet Alper; Çakir, Fatih; Gürgen, Selim; Orak, Sezan; Kuşhan, Melih Cemal

doi:10.1007/s40430-018-1037-4

Cited by 38 publications

(11 citation statements)

References 28 publications

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“…In this hybrid process, the interaction of the cutting tool and the workpiece directly takes place and the material is removed under the action of micro chipping [6]. Furthermore, the vibrations of the tool produce some surface texturing effect on the workpiece [7] and thereby good surface finishing, dimensional accuracy and low tool wear are obtained during machining [8]. The efficiency of UAT has been noted by various former researchers.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Power Consumption Associated with Surface Roughness in Ultrasonic Assisted Turning of Nimonic-90 Using Hybrid Particle Swarm-Simplex Method

et al. 2019

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These days, power consumption and energy related issues are very hot topics of research especially for machine tooling process industries because of the strict environmental regulations and policies. Hence, the present paper discusses the application of such an advanced machining process i.e., ultrasonic assisted turning (UAT) process with the collaboration of nature inspired algorithms to determine the ideal solution. The cutting speed, feed rate, depth of cut and frequency of cutting tool were considered as input variables and the machining performance of Nimonic-90 alloy in terms of surface roughness and power consumption has been investigated. Then, the experimentation was conducted as per the Taguchi L9 orthogonal array and the mono as well as bi-objective optimizations were performed with standard particle swarm and hybrid particle swarm with simplex methods (PSO-SM). Further, the statistical analysis was performed with well-known analysis of variance (ANOVA) test. After that, the regression equation along with selected boundary conditions was used for creation of fitness function in the subjected algorithms. The results showed that the UAT process was more preferable for the Nimconic-90 alloy as compared with conventional turning process. In addition, the hybrid PSO-SM gave the best results for obtaining the minimized values of selected responses.

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Section: Introductionmentioning

confidence: 99%

Optimization of Power Consumption Associated with Surface Roughness in Ultrasonic Assisted Turning of Nimonic-90 Using Hybrid Particle Swarm-Simplex Method

et al. 2019

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“…In terms of machining properties, life of cutting tools deteriorates due to the work hardening and attrition properties of Inconel 718. Furthermore, very high cutting forces cause metallurgical damage to the workpiece, such as work hardening, surface tearing, and distortion (Madariaga et al 2014;Sofuoğlu et al 2018a;Sofuoğlu et al 2018b). xx/xx 02/10…”

Section: Introductionmentioning

confidence: 99%

An Investigation on Surface Roughness and Tool Wear in Turning Operation of Inconel 718

Gürgen

Tali

Kuşhan

2019

J.Aerosp. Technol. Manag.

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This paper investigates the influences of three different input parameters, such as feed rate, insert nose radius, and insert coating methods, in the turning operation of Inconel 718. The coating methods were selected as medium temperature chemical vapor deposition (MT-CVD) and physical vapor deposition (PVD) and in addition to coating methods, the role of various coating materials was discussed since the inserts were coated with multi-layers of TiCN/Al2O3/TiN and single-layer of TiAlN on carbide substrates. The results were discussed in terms of wear behavior of cutting tools and surface quality of the workpiece, which is indicated by surface roughness. A full factorial experimental design was employed in the present work and the results were evaluated using main effects plots. Furthermore, the analysis of variance (ANOVA) method was applied to specify both reactive and non-reactive effects of experimental parameter reactions. The results showed that surface roughness is reduced using low feed rates and large nosed inserts in the operations. Furthermore, TiAlN-coated inserts with PVD method provided better surface finish than with MT-CVD method. It was also found that surface roughness increases as the wear rate of inserts increases.

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“…These parameter levels were determined according to past studies . 37,38,47 Taguchi L16 experimental design was used. Ti6Al4V was used as a workpiece material.…”

Section: Methodsmentioning

confidence: 99%

Investigation of electromechanical impedance and residual stress relation for samples machined by hot ultrasonic-assisted turning

Sofuoğlu

Haydarlar

Kuşhan

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Electromechanical impedance (EMI) method has been widely used in recent years to evaluate the condition of structures. In this method, piezoelectric sensors are added to the structure to examine material properties. The impedance/admittance signals are recorded with the aid of the impedance analyzer without any conversion. When there is any change in structures, differences occur in these signals. Thus, changes in structures can be easily determined. It is known that residual stress plays a vital role in materials in terms of crack initiation, breakage, fatigue life, etc. In contrast, the detection of residual stress is time-consuming and it requires experience. This study reveals the effect of cutting parameters on residual stress and electromechanical impedance/admittance values. Firstly, hot ultrasonic-assisted turning was performed for Ti6Al4V material. A parametric study was carried out with different cutting depth, feed rate, and cutting speed. In the second stage, residual stress values measured by X-Ray diffraction (XRD) method and impedance/admittance values measured by an impedance analyzer were compared. In this context, empirical equations with their values between stress/impedance–admittance values have been derived. In general, it has been observed that stress values are significantly associated with impedance/admittance values and the highest correlation was obtained with the reactance values.

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Numerical investigation of hot ultrasonic assisted turning of aviation alloys

Cited by 38 publications

References 28 publications

Optimization of Power Consumption Associated with Surface Roughness in Ultrasonic Assisted Turning of Nimonic-90 Using Hybrid Particle Swarm-Simplex Method

Optimization of Power Consumption Associated with Surface Roughness in Ultrasonic Assisted Turning of Nimonic-90 Using Hybrid Particle Swarm-Simplex Method

An Investigation on Surface Roughness and Tool Wear in Turning Operation of Inconel 718

Investigation of electromechanical impedance and residual stress relation for samples machined by hot ultrasonic-assisted turning

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