Investigation on Wear Behavior and Chip Formation During Up-Milling and Down-Milling Operations for Inconel 718

A comprehensive study and FEM simulation of ball nose end milling on tool wear behavior and chip formation had been performed on Inconel 718 (nickle-based superalloy) under minimum quantity lubricant (MQL) condition. In this paper, the investigation was focusing on the comparison of up-milling and down-milling operations using a multi-layer TiAlN/AlCrN-coated carbide inserts. A various cutting parameters; depth of cut, feed rate and cutting speed were considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear compared to up-milling operation. Chipping on cutting tool edge responsible to notch wear with prolong machining. It was observed that the chips formed in up-milling operation were segmented and continuous, meanwhile down-milling operation produced discontinuous type of chips

Comparison between Taguchi Method and Response Surface Methodology (RSM) In Optimizing Machining Condition

The application of Taguchi method and RSM to optimize the milling parameters when machining Aluminum silicon alloy (AlSic) matrix composite reinforced with aluminum nitride (AlN) with three types of carbide inserts is presented. Experiments were conducted at various cutting speeds, feed rates, and depth of cut according to Taguchi method using a standard orthogonal array L9 (34) and RSM historical data. The effects of cutting speeds, feed rates, depth of cut and types of tool on the surface roughness in milling operation were evaluated using Taguchi optimization methodology by utilizing the signal-to-noise (S/N) ratio and RSM optimization. Surface finish produced is very important in determining the quality of the machined part is within the specification and permissible tolerance limit. The analysis of results using S/N ratio concludes that the combination of low feed rate, low depth of cut, medium cutting speed and uncoated tool give a remarkable surface finish. Desirability criterion in RSM shows the optimum condition is at combination of high feed rate, high depth of cut, medium cutting speed and uncoated tool. In this case, the optimum condition obtained using Taguchi method is more accurate than RSM. Therefore it can be concluded that Taguchi method requires less number of experiment than RSM to determine an accurate optimum machining condition

Comparison between up-milling and down-milling operations on tool wear in milling Inconel 718

The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace industry as it is efficient for energy and has excellent properties. In this paper, the experimental studies of tool wear mechanism and tool life in ball nose end milling of Inconel 718 is presented under minimum quantity lubricant (MQL) condition. The evaluations of the results are focusing on the comparison of up-milling and down-milling operations using physical vapor deposition (PVD) - coated carbide inserts. Machining parameters; depth of cut, feed rate and cutting speed are considered during the valuation. The experimental results showed that down-milling operation has better results in terms of tool wear than up-milling operation. Chipping on cutting tool edge was the primary reason that responsible to notch wear with prolong machining

The Study Of Wear Process On Uncoated Carbide Cutting Tool In Machining Titanium Alloy

The uncoated carbide cutting tools were used in turning titanium alloy Ti6Al4V bar with hardness of 340HV. The main objective to find the wear behaviour of the cutting tool based on the flank wear data. The experiments were performed under dry cutting condition at various combinations of cutting speed and feed rate. The cutting speeds selected in the experiment were 15, 25, 35 and 45 m/min. Meanwhile the feed rates were used at 0.02 and 0.04 mm/rev. In this research depth of cut, doc was kept constant at 0.5 mm for all combinations of cutting parameters. Tool wear was measured under optical microscope and the data of flank wear which was gained through the experiment has been analysed. According to these graph shown that the affected of cutting parameters onto tool wear. The experiment’s result showed that the flank wear increased with the cutting speed and feed rate. The flank wear occurs gradually at beginning of machining and at the end of failure when Vbavg reached 0.3 mm where flank wear occurs

TOOL LIFE INVESTIGATION IN DRY TURNING OF INCONEL 718 WITH PVD TiAlN-COATED WC INSERT

Performance of tool life for coated carbide tool during turning Inconel 718 in dry condition was studied in order to increase the efficiency in turning process and reduce the machining cost. Coated carbide tool with thin layer of PVD TiAlN, CNMG 120408-QM 1105 was used to turn Inconel 718 with hardness 20.25 HRC. Taguchi method with the orthogonal array L9 was use in this experiment with the parameter v=60, 70, 80m/min, f=0.2,0.25,0.3mm/rev and d=0.3, 0.4, 0.5mm. Signal-to-noise ratio and analysis of variance (ANOVA) were employed to study the performance of tool life. According to results, cutting speed was significantly influence to the tool life, followed by feed rate and depth of cut. Increment in speed and feed rate will increase flank wear and shorten the tool life. v=60m/min, f=0.2mm/rev and d=0.3mm is the optimum parameter for tool life. It was discovered that flank wear rate gradually increase in the initial machining and accelerate significantly after flank wear width reach 0.1mm. Flank wear, crater wear, notch wear and nose wear are the wear occurs on the carbide tool during turning Inconel 718. Through the SEM, abrasion, attrition and adhesion are the wear mechanisms which can be seen on the cutting tool

Prestasi Perkakas Pemotong Karbida Bersalut Semasa Pengisaran Inkonel 718 Dalam Keadaan Kuantiti Pelincir Minimum

Inkonel merupakan salah satu dari keluarga aloi berasaskan Nikel. Ianya telah digunakan secara meluas di dalam bidang aeroangkasa, jana kuasa tenaga nuklear dan petrokimia disebabkan ciri-ciri istimewa bahan ini yang berkemampuan bertahan pada penggunaan suhu tinggi. Inkonel dikenali sebagai bahan sukar dimesin disebabkan sifat bahannya yang pelelas, keras dan kadar kebelaliran terma yang rendah. Ujikaji ini memfokuskan prestasi perkakas pemotong karbida dan kebolehmesinan Inkonel yang terdiri dari hayat mata alat, keutuhan permukaan dan daya pemotongan yang dijalankan dalam keadaan pelincir kuantiti minimum dengar kadar 50 ml/min. Ujikaji ini dijalankan berdasarkan kaedah metodologi permukaan sambutan (RSM) yang menggunakan pendekatan Box Behnken untuk melihat kesan faktor bersandar terhadap sambutan. Empat faktor dengan tiga peringkat yang dikaji menyasarkan jumlah 29 ujikaji. Faktor yang diambil kira dalam ujian ini ialah halaju pemotongan, Vc (100 – 140 m/min), kadar suapan (0.1 - 0.2 mm/gigi), kedalaman pemotongan paksi (0.5 – 1 mm) dan kedalaman pemotongan jejari (0.2 - 1.8 mm). Perkakas pemotong yang dipilih adalah jenis berbola yang dibuat dari tungsten karbida (WC-10% Co) dan disalut secara pengendapan wap fizik (PVD) dengan TiAlN dan AlCrN. Melalui kajian ini, haus rusuk setempat, VB3 didapati mod kegagalan yang paling dominan berbanding mod haus yang lain. Pembentukan VB3 ini disebabkan oleh haus takuk. Oleh yang demikian, nilai VB3 dipilih sebagai penentuan kegagalan mata alat apabila nilai had haus mencecah 0.5 mm. Pencerapan haus dilakukan dengan menggunakan mikroskop pembuat mata-alat, manakala kekasaran permukaan diukur menggunakan Pengukur kekasaran permukaan Mahr Perthometer. Daya yang terhasil semasa proses pemotongan diukur dan direkodkan menggunakan dynamometer Kistler model 5070A. Ketika proses pemotongan, didapati berlaku pembentukan serpihan yang berubah dari serpihan individu pada awal pemesinan kepada serpihan berkembar sebagai penanda zon kritikal di akhir hayat perkakas. ANOVA digunakan untuk kenal pasti kesan faktor yang signifikan terhadap respons. Melalui analisis yang dilakukan, didapati kedalaman pemotongan jejari adalah yang paling mempengaruhi jangka hayat mata alat, selain daripada laju pemotongan, kadar suapan dan kedalaman pemotongan paksi. Bagi analisis kekasaran permukaan, didapati gabungan antara kadar suapan dan kedalaman pemotongan jejari merupakan yang paling signifikan yang menentukan nilai kekasaran permukaan. ANOVA terakhir mendapati daya paduan secara signifikan dipengaruhi oleh kedalaman pemotongan jejari dan paksi. Model matematik dibangunkan berdasarkan ketiga-tiga sambutan; hayat mata alat, kekasaran permukaan dan daya paduan dengan kadar purata ralat 5.2 min (25%), 0.01 μm (4%) dan 6.6 N (2%). Ralat yang besar untuk jangka hayat perkakas disebabkan fenomena kerosakan perkakas yang berlaku berdasarkan kebarangkalian. Peluang haus takuk mencapai nilai 0.5 mm didapati lebih tinggi pada nilai kedalaman jejari yang besar, Kombinasi parameter optimum yang menghasilkan sambutan yang paling dikehendaki ialah Vc = 100 m/min, fz = 0.15 mm/gigi, ap = 0.5 mm dan ae = 0.66 mm yang menghasilkan jangka hayat 59.4 min, kekasaran serendah 0.262 μm, daya gabungan 221 N dengan jumlah maksimum bahan dibuang sebanyak 9029 mm3. Daripada kajian ini, walaupun Inkonel ini sukar dimesin, penggunaan mata pemotong telah diminimumkan untuk pemesinan akhir sambil mengekalkan kekasaran permukaan yang baik

Experimental Investigation of Significance Parameters in Surface Grinding – Quality Evaluation

The resurgence of the high quality and precision parts by manufacturing industries has enabled the development of ultraprecision machine tools. Surface roughness and tolerances are the most critical quality measures of any mating mechanical parts produced. The quality evaluation requirement of manufactured parts is becoming the prime factor as it determines not only the esthetics values, but also the lifespan and function of its purpose. Grinding is one the most popular methods of machining hard materials which widely known as random point cutting. The main aim of this experimental work is to investigate the significant parameter(s) in surface grinding which affect the machined surface roughness. Two work materials, namely, mild steel and carbon steel have been investigated with two variables; feed rate and depth of cut for the response of surface roughness totaling eight experiments with three replications. Statistical approach using Design of Experiment (DOE) has been carried out in this investigation. The ANOVA results of the analysis have been based to determine the significance and correlation of the input and output parameters

PREDICTION SURFACE ROUGHNESS IN HIGH-SPEED MILLING OF INCONEL 718 UNDER MQL USING RSM METHOD

This paper investigates the effect of cutting speed, feed rate, and depth of cut on the surface roughness of Inconel 718 when milled under minimum quantity lubrication. The response surface methodology (RSM) was employed in the experiment, and a Box–Behnken design was used to determine the cause and effect of the relationship between the control variables and the response. The investigated milling parameters were cutting speed (100, 135, and 170 m/min), feed rate (0.15, 0.2, and 0.25 mm/rev), and depth of cut (0.6, 0.8, and 1.0 mm). The results showed that the interaction between the feed rate, fz, and the radial depth of cut, ae, was the primary factor controlling surface roughness. The responses of various factors were plotted using a three-dimensional surface graph. The quadratic empirical models were developed with a 95% confidence level. The optimum condition required for minimum surface roughness include cutting speed of 136 m/min, feed rate of 0.1 mm/rev, axial depth of cut of 0.5 mm, and radial depth of cut of 1.38 mm. With this optimum condition, a surface roughness of 0.117 µm was obtained

Mechanical and Thermal Properties of Single-Walled Carbon Nanotube Filled Epoxidized Natural Rubber Nanocomposite

The use of Single-Walled Carbon Nanotube (SWCNT) as a reinforcement in rubber nano composite nowadays attracts a great deal of attention. Rubber used in this study was Epoxidized Natural Rubber (ENR) and was incorporated with SWCNT as nano filler. The influence of SWCNT nanofiller on mechanical and thermal properties of the produced nanocomposite was studied. The nanocomposite were prepared by using Haake internal mixer with 0, 5, 10 and 15 parts per hundred rubber of the SWCNT and the detailed preparation method is presented. Mechanical properties were evaluated by means of tensile and hardness tests under different SWCNT composition. As results, the strength and elongation at break of the nanocomposite decreased and simultaneously, the strength modulus and hardness increased. Moreover, from the differential scanning calorimetry analysis, the value of melting temperature (Tm), crystalline temperature (Tc) and heat transition (ΔH) were found increased with the increasing ratio of SWCNT

An Investigation of the Impact of Cylindrical Grinding Parameters on Surface Roughness

This paper presented an investigation of impact of cylindrical grinding parameter to surface roughness on SUS316 stainless steel. Grinding is the most common process when the workpiece demands good surface, dimensional and geometrical quality. In this experiment, the finding is the actual effect of surface roughness and the relationship for each parameter that have been choosing. The method that has been used to design the experiment was Design of Experiment (DOE) full factorial with two levels. The surface roughness of the workpiece has been analyzed by using a Portable Roughness Measurement Machine. The data will be compared and analyzed using MINITAB 14 software. The graphs have been created to shows the optimum factor and interaction between the factors. This experiment runs using three factors which are traverse speed, work speed and depth of cut