Tool wear and hole quality evaluation in cryogenic Drilling of Inconel 718 superalloy

Khanna, Navneet; Agrawal, Chetan; Gupta, Munish Kumar; Song, Qinghua

doi:10.1016/j.triboint.2019.106084

Cited by 88 publications

(20 citation statements)

References 53 publications

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“…Nevertheless, they did not present any model based on the measurement results. Khanna et al [ 24 ] checked what effect flood cooling or no cooling had on the hole quality (cylindricity and roundness). They did not, however, change any input process parameter.…”

Section: Introductionmentioning

confidence: 99%

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Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel

2021

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This article discusses the relationship between the kinematic system used in drilling and the quality of through-holes. The drilling was done on a CTX Alpha 500 universal turning center using a TiAlN-coated 6.0 mm drill bit with internal cooling, mounted in a driven tool holder. The holes were cut in cylindrical 42CrMo4 + QT steel samples measuring 30 mm in diameter and 30 mm in length. Three types of hole-drilling kinematic systems were considered. The first consisted of a fixed workpiece and a tool performing rotary (primary) and linear motions. In the second system, the workpiece rotated (primary motion) while the tool moved linearly. In the third system, the workpiece and the tool rotated in opposite directions; the tool also moved linearly. The analysis was carried out for four output parameters characterizing the hole quality (i.e., cylindricity, straightness, roundness, and diameter errors). The experiment was designed using the Taguchi approach (orthogonal array). ANOVA multi-factor statistical analysis was used to determine the influence of the input parameters (cutting speed, feed per revolution and type of kinematic system) on the geometrical and dimensional errors of the hole. From the analysis, it is evident that the kinematic system had a significant effect on the hole roundness error.

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Section: Introductionmentioning

confidence: 99%

“…The analysis indicated that the rotational speed of the spindle was one of the most important factors affecting hole diameter (approximately 42%). The investigations described in [ 24 ] focused on hole roundness analyzed in relation to feed rate for three different cutting speeds.…”

Section: Introductionmentioning

confidence: 99%

Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel

2021

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“…The experiments showed that the hole roundness error was mainly dependent on the kinematic system (65%); the influence of the cutting speed and feed per revolution was much smaller (16% and 6%, respectively). Khanna et al analyzed the behavior of Inconel 718 in cryogenic drilling and dry drilling at constant process parameters (f n = 0.02 mm/rev and v c = 19 m/min), and the output parameters were the hole roundness and cylindricity errors [ 20 ]. Sandeep, Ajay, and Jagadesh investigated the effects of graphite, MOS 2 , and Blasocut lubricants on the hole diameter and cylindricity errors [ 21 ].…”

Section: Introductionmentioning

confidence: 99%

Influence of the Kinematic System on the Geometrical and Dimensional Accuracy of Holes in Drilling

Bronis¹,

Miko²,

Nowakowski³

2021

Materials

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This article attempts to show how the kinematic system affects the geometrical and dimensional accuracy of through-holes in drilling. The hole cutting tests were performed using a universal turning center. The tool was a TiAlN-coated Ø 6 mm drill bit, while the workpiece was a C45 steel cylinder with a diameter of 30 mm and a length of 30 mm. Three kinematic systems were studied. The first consisted of a fixed workpiece and a rotating and linearly moving tool. In the second, the workpiece rotated, while the tool moved linearly. The third system comprised a rotating workpiece and a rotating and linearly moving tool, but they rotated in opposite directions. The geometrical and dimensional accuracy of the hole was assessed by analyzing the cylindricity, straightness, roundness, and diameter errors. The experiment was designed using the Taguchi orthogonal array method to determine the significance of the effects of the input parameters (cutting speed, feed per revolution, and type of kinematic system) on the accuracy errors. A multifactorial statistical analysis (ANOVA) was employed for this purpose. The study revealed that all the input parameters considered had a substantial influence on the hole quality in drilling.

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“…Rajmohan et al [11] optimized the drilling parameters of Al356/SiC-mica metal matrix composites and revealed that feed rate is a dominant parameter in tool wear, surface finish, burr height and thrust force. Chakravarthy et al [12] investigated cryogenic drilling of SiC-reinforced AMC with carbide tools, while Khanna et al [13] investigated the cryogenic drilling of Inconel 718 steel. Carbide drill bits with 90 • tool angle could result in the minimum surface roughness and burr height.…”

Section: Introductionmentioning

confidence: 99%

Drilling Parameters Analysis on In-Situ Al/B4C/Mica Hybrid Composite and an Integrated Optimization Approach Using Fuzzy Model and Non-Dominated Sorting Genetic Algorithm

Palanikumar¹,

Krishnan

Natarajan

et al. 2021

Metals

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In-situ hybrid metal matrix composites were prepared by reinforcing AA6061 aluminium alloy with 10 wt.% of boron carbide (B4C) and 0 wt.% to 6 wt.% of mica. Machinability of the hybrid aluminium metal matrix composite was assessed by conducting drilling with varying input parameters. Surface texture of the hybrid composites and morphology of drill holes were examined through scanning electron microscope images. The influence of rotational speed, feed rate and % of mica reinforcement on thrust force and torque were studied and analysed. Statistical analysis and regression analysis were conducted to understand the significance of each input parameter. Reinforcement of mica is the key performance indicator in reducing the thrust force and torque in drilling of the selected material, irrespective of other parameter settings. Thrust force is minimum at mid-speed (2000 rpm) with the lowest feed rate (25 mm/min), but torque is minimum at highest speed (3000 rpm) with lowest feed rate (25 mm/min). Multi-objective optimization through a non-dominated sorting genetic algorithm has indicated that 1840 rpm of rotational speed, 25.3 mm/min of feed rate and 5.83% of mica reinforcement are the best parameters for obtaining the lowest thrust force of 339.68 N and torque of 68.98 N.m. Validation through experimental results confirms the predicted results with a negligible error (less than 0.1%). From the analysis and investigations, it is concluded that use of Al/10 wt.% B4C/5.83 wt.% mica composite is a good choice of material that comply with European Environmental Protection Directives: 2000/53/CE-ELV for the automotive sector. The energy and production cost of the components can be very much reduced if the found optimum drill parameters are adopted in the production.

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Tool wear and hole quality evaluation in cryogenic Drilling of Inconel 718 superalloy

Cited by 88 publications

References 53 publications

Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel

Analyzing the Effects of the Kinematic System on the Quality of Holes Drilled in 42CrMo4 + QT Steel

Influence of the Kinematic System on the Geometrical and Dimensional Accuracy of Holes in Drilling

Drilling Parameters Analysis on In-Situ Al/B4C/Mica Hybrid Composite and an Integrated Optimization Approach Using Fuzzy Model and Non-Dominated Sorting Genetic Algorithm

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