Microstructural and surface texture analysis due to machining in Super Austenitic Stainless Steel

Inferior surface quality is a significant problem faced by machinist. The purpose of this study is to present a surface texture analysis undertaken as part of machinability assessment of Super Austenitic Stainless Steel alloy-AL6XN. The surface texture analysis includes measuring the surface roughness and investigating the microstructural behaviour of the machined surfaces. Eight milling trials were conducted using combination of cutting parameters under wet machining. An optical profilometer (non-contact), was used to evaluate the surface texture at three positions. The surface texture was represented using the parameter, average surface roughness. Scanning Electron Microscope was utilised to inspect the machined surface microstructure and co relate with the surface roughness results. Results showed that maximum roughness values recorded at the three positions in the longitudinal direction (perpendicular to the machining grooves) were 1.21 μm (trial 1), 1.63 μm (trial 6) and 1.68 μm (trial 7) respectively whereas the roughness values were greatly reduced in the lateral direction. Also, results showed that the feed rate parameter significantly influences the roughness values compared to the other cutting parameters. The microstructure of the machined surfaces was distorted by the existence of cracks, deformed edges and bands and wear deposition due to machining process

A preliminary assessment of machinability of titanium alloy Ti 6Al 4V during thin wall machining using trochoidal milling

Titanium alloys are of great demand in the aerospace and biomedical industries. Most the titanium products are either cast or sintered to required shape and finish machined to get the appropriate surface texture to meet the design requirements. Ti-6Al-4V is often referred as work horse among the titanium alloys due to its heavy use in the aerospace industry. This paper is an attempt to investigate and improve the machining performance of Ti-6Al-4V. Thin wall machining is an advance machining technique especially used in machining turbine blades which can be done both in a conventional way and using a special technique known as trochoidal milling. The experimental design consists of conducting trials using combination of cutting parameters such as cutting speed (vc), 90 and 120 m/min; feed/tooth (fz) of 0.25 and 0.35 mm/min; step over (ae) 0.3 and 0.2; at constant depth of cut (ap) 20mm and using coolant. A preliminary assessment of machinability of Ti-6Al-4V during thin wall machining using trochoidal milling is done. A correlation established using cutting force, surface texture and dimensional accuracy

Heat Treatment Effect on the Fatigue Characteristics of Additive Manufactured Stainless Steel 316L

Stainless steel is an age old and popular alloy known for its high corrosion resistance. This paper is an attempt to explore ways to enhance the fatigue characteristics using heat treatment. The additive manufacturing technique used in this paper is based on Selective Laser Melting (SLM). The material used in this paper is SLM Stainless steel 316L. The specimen printed using SLM technique are subjected to low cycle fatigue tests as per the ASTM standards. Out of the twelve printed specimens, two sets for as-built and heat-treated were separated. A set of six was heat-treated at recrystallisation temperature of 700o C for 2 hours and air cooled. Two specimen each for the as-built and heat-treated category were reserved for tensile testing to evaluate the yield strength, ultimate tensile strength and strain. The remaining eight printed specimen of as-built and heat-treated were allotted for fatigue testing (four each of as-built and heat-treated). After tensile tests, fatigue tests were conducted on the specimens at mean stress equals to 75%, 70%, 65% and 60% of tensile strength, keeping stress ratio, r = 0.5 and at frequency of 5 Hz. Number of cycles to failure were obtained for each specimen for similar loading conditions to plot the S-N curve. The paper concludes by making an analogy in the fatigue characteristic of as-built and heat-treated specimen

Recent advances in machining of Austempered Ductile Iron to avoid machining induced microstructural phase transformation reaction

Austempered Ductile Iron (ADI) is a type of nodular, ductile cast iron subjected to heat treatments-austenitising and austempering. Whilst machining is conducted prior to heat treatment and offers no significant difficulty, machining post heat treatment is demanding and often avoided. Phase transformation of retained austenite to martensite leading to poor machinability characteristics is a common problem experienced during machining. Study of phase transformations is an investigative study on the factors-plastic strain (εp) and thermal energy (Q) which effect phase transformations during machining. The experimental design consists of face milling grade 1200 at variable Depth of Cut (DoC) range from 1 to 4 mm, coolant on/off, at constant speed, 1992 rpm and feed rate, 0.1 mm/tooth. Plastic strain (εp) and martensite content (M) at fracture point for each grade was evaluated by tensile testing. The effect of thermal energy (Q) on phase transformations was also verified through temperature measurements at DoC 3 and 1 mm using thermocouples embedded into the workpiece. Finally, the amount of plastic strain (εp) and thermal energy (Q) responsible for a given martensite increase (M) during milling was related and calculated using a mathematical function, M=f (εp, Q). The future work of the thesis involves an in-depth study on the new link discovered through this research: mathematical model relating the role of plastic strain and thermal energy in martensite formation

Machinability assessment of titanium alloy Ti-6Al-4V for biomedical applications

Titanium alloy (Ti-6Al-4V) has a wide range of application in various fields of engineering. Titanium is mainly used to manufacture aerospace components like landing gear, fuselage, wings, engines etc. and biomedical components like hip joint, knee joint, dental implants etc. Titanium has outstanding material properties such as corrosion resistance, fatigue strength, tensile strength and a very good biocompatibility which makes this material very alluring for biomedical applications. Contrary, the machinability of the material is problematic because of the phase transformations and thus, titanium alloy is a challenge for machining operation. This research is a comparative analysis between the implants manufactured by traditional method of casting and machining. The femoral stem of the hip joint replacement is designed and the component is machined using a five-axis CNC machine.The machined component was subjected to surface roughness testing, tensile testing and bulk hardness testing. The values were compared with the values of titanium implants manufactured by casting. © (2014) Trans Tech Publications, Switzerland

Robotic grasping and manipulation controller framework: architecture redevelopment

This paper details the further improvements obtained by redesigning a previously offered Manipulation Controller Framework to provide support to an innovative, friction-based object slippage detection strategy employed by the robotic object manipulator. This upgraded Manipulation Controller Framework includes improved slippage detection functionality and a streamlined architecture designed to improve controller robustness, reliability and speed. Improvements include enhancements to object slippage detection strategy, the removal of the decision making module and integration of its functionality into the Motion Planner, and the stream-lining of the Motion Planner to improve its effectiveness. It is anticipated that this work will be useful to researchers developing integrated robot controller architectures and slippage control

Slot machining of TI6AL4V with trochoidal milling technique

Titanium usage for aerospace growing day by day as application of titanium and its alloys covers wide range. Most of the aerospace components made up of wall structure involves lot of pocket slot milling since those components are monolithic components, eliminating need to manufacture multiple pieces for assembly into one final part. The increasing complexity of titanium parts used in aviation industry, increasing demand for productive manufacturing methods like trochoidal milling. This paper aims at evaluating its potential in slot milling for Ti6Al4V component by conducting experiments on 5-axis CNC machine. This study focuses on Productivity, Quality and Machine Tool Dynamics