Tool Wear Analysis during Ultrasonic Assisted Turning of Nimonic-90 under Dry and Wet Conditions

Airao, Jay; Nirala, Chandrakant K.; Lacalle, Luís Norberto López de; Khanna, Navneet

doi:10.3390/met11081253

Cited by 21 publications

(4 citation statements)

References 40 publications

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“…Due to the poor thermal conductivity of nickel-based alloys, the resulting increased shear stress leads to serious tool wear in traditional processing. Due to the influence of intermittent separation cutting characteristics in UVAM, the separation between the tool and the workpiece has a low contact ratio, thus reducing tool wear [47] and extending the tool life during cutting Inconel718 by 250% [48]. It also reduces the accumulation of tool edges, thereby reducing tool side wear [42].…”

Section: Tool Wearmentioning

confidence: 99%

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Gu,

Wang,

et al. 2024

Intelligent and Sustainable Manufacturing

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Nickel-based alloys has important application value in modern industrial field, but there are a lot of problems that are difficult to solve in traditional processing, and it is a typical difficult-to-process material. In order to improve the machinability of nickel-based alloys, scholars try to use a variety of non-traditional processing methods to explore and study the processing of nickel-based alloys. In these studies, ultrasonic vibration assisted processing technology and minimum quantity lubrication (MQL) processing technology can achieve remarkable results. The intermittent separation cutting characteristics of ultrasonic vibration assisted processing technology can improve the processing quality by changing the tool path, while minimum quantity lubrication processing technology can improve the lubrication effect of cutting, combining ultrasonic vibration assisted MQL processing leverages the benefits of both methods, resulting in improved machinability and expanded application of nickel-based alloys. Summarize the current research status on the machining mechanism of nickel-based alloys assisted by ultrasonic vibration and micro lubrication, and anticipate its developmental trends. This provides a reference for future research on the efficient machining mechanisms and practical applications of nickel-based alloys.

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Section: Tool Wearmentioning

confidence: 99%

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Gu,

Wang,

et al. 2024

Intelligent and Sustainable Manufacturing

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“…The aim of Lapshin's article [64] was to estimate the wear rate of a tool indirectly, based on a consistent model between systems designed for the force, heat and vibration conditions of the cutting process. In an article by Airao et al [65], they investigated how ultrasonic vibration affects tool wear when a coated carbide insert is used for machining Nimonic-90 nickel-based superalloy in dry and wet conditions.…”

Section: State Of the Art Of Surface Roughness And Wear Modeling In H...mentioning

confidence: 99%

Theoretical Roughness Modeling of Hard Turned Surfaces Considering Tool Wear

Felhő

Varga

2022

Machines

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Surface roughness is an important factor in metal cutting, and usually different surface roughness characteristics are used to control the quality of the machined surfaces. However, as the cutting tool wears out during the cutting process, the roughness values change. In most cases, theoretical roughness values are calculated without taking the wear characteristics of the tool into account. For this reason, the calculated and measured roughness values may differ from each other, and the tendency of their change may also be different. This paper presents a method for the determination of the theoretical roughness of hard turned surfaces considering the wear of the cutting tool. The purpose of the analyses performed was to show the effect of wear trace on the tool and the roughness of the machined surface and to give a possible method to take the wear into account when calculating the theoretical roughness values. During the investigations, the shape of the actual (worn) edge section of the cutting tool was recorded by an optical microscope, and the theoretical surface roughness values were calculated with that profile by a CAD modeling method developed earlier. Cutting experiments were conducted on a lathe machine with two similar cutting tools, one of them has significant tool wear, while the other was a completely new one. The calculated theoretical roughness values were compared with real measured roughness values, and the error of the estimates was between 8.7 and 68.3%, larger errors were found at lower feeds.

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“…In the past, experiments and simulations have been used to study and improve the machinability of hard-to-cut alloys. These improvements were achieved by enhancing the machining capabilities [ 3 , 4 , 5 , 6 ], hybrid machining techniques [ 7 ], cryogenic coolant application [ 8 ], minimum lubricant quantity [ 9 ], and alloy modification without compromising the mechanical properties of the alloy [ 10 ]. The theory of ultrasonic machining has been successfully applied to face milling and drilling operations, and significant improvements in terms of the surface quality of the finished product has been achieved [ 11 , 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

A Fuzzy Logic Model for the Analysis of Ultrasonic Vibration Assisted Turning and Conventional Turning of Ti-Based Alloy

Muhammad

2021

Materials

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Titanium and its alloys are largely used in various applications due its prominent mechanical properties. However, the machining of titanium alloys is associated with assured challenges, including high-strength, low thermal conductivity, and long chips produced in conventional machining processes, which result in its poor machinability. Advanced and new machining techniques have been used to improve the machinability of these alloys. Ultrasonic vibration assisted turning (UVAT) is one of these progressive machining techniques, where vibrations are imposed on the cutting insert, and this process has shown considerable improvement in terms of the machinability of hard-to-cut alloys. Therefore, selecting the right cutting parameters for conventional and assisted machining processes is critical for obtaining the anticipated dimensional accuracy and improved surface roughness of Ti-alloys. Hence, fuzzy-based algorithms were developed for the ultrasonic vibration assisted turning (UVAT) and conventional turning (CT) of the Ti-6Al7Zr3Nb4Mo0.9Nd alloy to predict the maximum process zone temperature, cutting forces, surface roughness, shear angle, and chip compression ratio for the selected range of input parameters (speed and depth-of-cut). The fuzzy-measured values were found to be in good agreement with the experimental values, indicating that the created models can be utilized to accurately predict the studied machining output parameters in CT and UVAT processes. The studied alloy resulted in discontinued chips in both the CT and UVAT processes. The achieved results also demonstrated a significant decline in the cutting forces and improvements in the surface quality in the UVAT process. Furthermore, the chip discontinuity is enhanced by the UVAT process due to the higher process zone temperature and the micro-impact imposed by the cutting tool on the workpiece.

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Tool Wear Analysis during Ultrasonic Assisted Turning of Nimonic-90 under Dry and Wet Conditions

Cited by 21 publications

References 40 publications

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

Theoretical Roughness Modeling of Hard Turned Surfaces Considering Tool Wear

A Fuzzy Logic Model for the Analysis of Ultrasonic Vibration Assisted Turning and Conventional Turning of Ti-Based Alloy

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