Machinability Improvement During High-speed End-milling of Inconel 718 Alloy PDF Download
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Author: Chukwujekwu Ikwy Nnadi
Publisher:
ISBN:
Category :
Languages : en
Pages : 167
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Book Description
"This thesis presents the results of the experimental investigation of the effects of machining parameters (spindle speed and feedrate) and cooling strategies [Minimum Quantity Lubrication (MQL), Cryogenic Liquid Nitrogen (LN2), and combined (MQL+LN2)] on cutting force components, cutting temperature, tool wear and surface roughness during high-speed slot end-milling of Inconel 718 alloy. In addition, a comparative evaluation of the three cooling strategies was conducted for cutting force components, surface roughness and residual stresses. All end-milling experiments were conducted on a Cincinnati Milacron Vertical Machining center (VMC), using a 0.5 inch (12.7 mm) diameter, 0.03 inch (0.762 mm) corner radius four-flute uncoated carbide end-mill. A one-third fractional factorial design of experiments was constructed (nine experimental runs) and used in analyzing all experimental results. Cutting force components were acquired using a Kistler type 9272 4-component dynamometer, which was connected to an amplifier and a junction box. Cutting temperature was measured using a 0.125 inch (3.175 mm) diameter ungrounded k-type thermocouple, while tool wear was investigated indirectly by analyzing the maximum cutting force components of the last two passes (19 and 20). Surface roughness and residual stresses were measured using a profilometer and X-ray diffraction respectively. The results showed that high spindle speed (750 rpm) and medium feed rate (2 ipm) gave the lowest cutting force components, while low spindle speed (250 rpm) gave the lowest cutting temperature and tool wear. Furthermore, a low spindle speed (250 rpm) and feed rate (1 ipm) gave the least surface roughness, while MQL cooling strategy induced the highest compressive stresses"--Abstract, page iv.
Author: Chukwujekwu Ikwy Nnadi
Publisher:
ISBN:
Category :
Languages : en
Pages : 167
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Book Description
"This thesis presents the results of the experimental investigation of the effects of machining parameters (spindle speed and feedrate) and cooling strategies [Minimum Quantity Lubrication (MQL), Cryogenic Liquid Nitrogen (LN2), and combined (MQL+LN2)] on cutting force components, cutting temperature, tool wear and surface roughness during high-speed slot end-milling of Inconel 718 alloy. In addition, a comparative evaluation of the three cooling strategies was conducted for cutting force components, surface roughness and residual stresses. All end-milling experiments were conducted on a Cincinnati Milacron Vertical Machining center (VMC), using a 0.5 inch (12.7 mm) diameter, 0.03 inch (0.762 mm) corner radius four-flute uncoated carbide end-mill. A one-third fractional factorial design of experiments was constructed (nine experimental runs) and used in analyzing all experimental results. Cutting force components were acquired using a Kistler type 9272 4-component dynamometer, which was connected to an amplifier and a junction box. Cutting temperature was measured using a 0.125 inch (3.175 mm) diameter ungrounded k-type thermocouple, while tool wear was investigated indirectly by analyzing the maximum cutting force components of the last two passes (19 and 20). Surface roughness and residual stresses were measured using a profilometer and X-ray diffraction respectively. The results showed that high spindle speed (750 rpm) and medium feed rate (2 ipm) gave the lowest cutting force components, while low spindle speed (250 rpm) gave the lowest cutting temperature and tool wear. Furthermore, a low spindle speed (250 rpm) and feed rate (1 ipm) gave the least surface roughness, while MQL cooling strategy induced the highest compressive stresses"--Abstract, page iv.
Author: J. Paulo Davim
Publisher: Springer
ISBN: 3662439026
Category : Technology & Engineering
Languages : en
Pages : 154
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Book Description
This book presents a collection of examples illustrating the resent research advances in the machining of titanium alloys. These materials have excellent strength and fracture toughness as well as low density and good corrosion resistance; however, machinability is still poor due to their low thermal conductivity and high chemical reactivity with cutting tool materials. This book presents solutions to enhance machinability in titanium-based alloys and serves as a useful reference to professionals and researchers in aerospace, automotive and biomedical fields.
Author: A.K.M. Nurul Amin
Publisher: LAP Lambert Academic Publishing
ISBN: 9783659439933
Category :
Languages : en
Pages : 196
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Book Description
Inconel 718 is the most widely used in the aerospace industries, especially for gas turbine hot section components. Titanium alloys, on the other hand, have very high strength-to-weight ratio making them very suitable for aircraft engines and airframe manufacture. They account for 30% of the total engine mass in commercial and 40% in military projects. However, both these strategic materials have poor machinability, as a result of which they have dominated the major research interests in metal cutting industries in the past decades. One of the techniques to improve machinability is the use an external heat source during machining. LAM applications offered significantly lower cutting force, higher metal removal rate and smoother surface finish, however, high costs of lasers slowed down its implementation. A new approach is heat assisted machining using inducting heating suitable for end milling operation. This book reports a comparative analysis of machinability of these two very strategic materials and their behavior to induction heat assisted machining in terms of tool wear, cutting forces, surface roughness and vibration/chatter.
Author: Viktor P. Astakhov
Publisher: Elsevier
ISBN: 0080466850
Category : Technology & Engineering
Languages : en
Pages : 451
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Book Description
Tribology of Metal Cutting deals with the emerging field of studies known as Metal Cutting Tribology. Tribology is defined as the science and technology of interactive surfaces moving relative each other. It concentrates on contact physics and mechanics of moving interfaces that generally involve energy dissipation. This book summarizes the available information on metal cutting tribology with a critical review of work done in the past. The book covers the complete system of metal cutting testing. In particular, it presents, explains and exemplifies a breakthrough concept of the physical resource of the cutting tool. It also describes the cutting system physical efficiency and its practical assessment via analysis of the energy partition in the cutting system. Specialists in the field of metal cutting will find information on how to apply the major principles of metal cutting tribology, or, in other words, how to make the metal cutting tribology to be useful at various levels of applications. The book discusses other novel concepts and principles in the tribology of metal cutting such as the energy partition in the cutting system; versatile metrics of cutting tool wear; optimal cutting temperature and its use in the optimization of the cutting process; the physical concept of cutting tool resource; and embrittlement action. This book is intended for a broad range of readers such as metal cutting tool, cutting insert, and process designers; manufacturing engineers involved in continuous process improvement; research workers who are active or intend to become active in the field; and senior undergraduate and graduate students of manufacturing. · Introduces the cutting system physical efficiency and its practical assessment via analysis of the energy partition in the cutting system.· Presents, explains and exemplifies a breakthrough concept of the physical resource of the cutting tool.· Covers the complete system of metal cutting testing.
Author: Mohammad Istiyaq Hossain
Publisher:
ISBN:
Category : Aeronautics
Languages : en
Pages : 420
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Book Description
Aerospace alloys such as nickel based superalloy Inconel 718 as well as titanium based T1-6A1-4V are generally regarded as difficult to cut materials. Numerous research works have been conducted on their machinability in the past few decades with the main objective of reducing cost of machining. Though classified as "difficult-to-cut" materials, they are attractive materials due to their high strength, which is maintained up to elevated temperatures and their exceptional corrosion resistance. Induction preheating is one of the new variable parameters to improve the machinability of Inconel 718 and Ti-6A1-4V. In the current work the influence of heating parameter i.e. preheating temperature; cutting variable, such as cutting speed, feed and axial depth of cut were investigated during end milling operation on a CNC Vertical Machining Center (VMC). The inserts used were TiAIN coated carbide filled onto a 20 mm diameter end mill tool. The machining experiments were conducted under room temperature and preheated conditions. Response Surface Methodology (RSM) was used to develop empirical models of tool life, cutting force and surface roughness both for room temperature and preheated machining conditions using the data generated from the machining experiments. The developed RSM models for tool life were further coupled with Genetic Algorithm (GA) to maximise metal removal per tool life by optimising the cutting conditions and preheating temperature. The comparison between room temperature and preheated machining were made in terms of tool life, cutting force, surface roughness and machine tool vibration. It was found that preheating had reduced the tool wear, surface roughness, vibration/chatter amplitudes and chip formation stability to a desired level.
Author: Kapil Gupta
Publisher: Academic Press
ISBN: 0128150211
Category : Technology & Engineering
Languages : en
Pages : 328
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Book Description
High-Speed Machining covers every aspect of this important subject, from the basic mechanisms of the technology, right through to possible avenues for future research. This book will help readers choose the best method for their particular task, how to set up their equipment to reduce chatter and wear, and how to use simulation tools to model high-speed machining processes. The different applications of each technology are discussed throughout, as are the latest findings by leading researchers in this field. For any researcher looking to understand this topic, any manufacturer looking to improve performance, or any manager looking to upgrade their plant, this is the most comprehensive and authoritative guide available. - Summarizes important R&D from around the world, focusing on emerging topics like intelligent machining - Explains the latest best practice for the optimization of high-speed machining processes for greater energy efficiency and machining precision - Provides practical advice on the testing and monitoring of HSM machines, drawing on practices from leading companies
Author: Xian Li Liu
Publisher: Trans Tech Publications Ltd
ISBN: 303826525X
Category : Technology & Engineering
Languages : en
Pages : 902
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Book Description
Collection of selected, peer reviewed papers from the 6th International Conference on High Speed Machining (ICHSM2014), July 24-25, 2014, Harbin, China. The 160 papers are grouped as follows: Chapter 1: Mechanisms and Machining Process, Chapter 2: Modeling and Simulation of Machining Processes, Chapter 3: Machine Tools and Cutting Tools, Chapter 4: Surface Integrity of Machining Processes, Chapter 5: CAD/CAM and Process Optimization, Chapter 6: Testing, Measuring and Monitoring of Processing, Chapter 7: Micro-Machining and Non-Traditional Machining Technologies
Author: M. Shafik
Publisher: IOS Press
ISBN: 1643683314
Category : Technology & Engineering
Languages : en
Pages : 416
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Book Description
Within the context of Industrial 4.0 and beyond, developing and managing the technologies and operations key to sustaining the success of manufacturing businesses is crucial, and the promotion of manufacturing-engineering education, training, and research is of vital importance. This book presents the proceedings of ICMR 2022, the 19th International Conference in Manufacturing Research, Incorporating the 36th National Conference in Manufacturing Research, held in Derby, UK, from 6 - 8 September 2022. For over two decades, ICMR has been the main manufacturing research conference held in the UK. Bringing together researchers, academics, and industrialists to share their knowledge and experience, the conference provides a friendly and inclusive platform for a broad community of researchers who share the common goal of making digital and advanced manufacturing as efficient and effective as possible. The theme of ICMR2022 is smart manufacturing. Of the 78 papers submitted, 58 were accepted for presentation after review and are included here. This represents an acceptance rate of 72%. The book is divided into 8 sections: smart manufacturing; digital manufacturing; additive manufacturing; robotics and industrial automation; composite manufacturing and machining processes; product design, development and quality management; information and knowledge management; and decision support and production optimization. Exploring all core areas of digital and advanced manufacturing engineering, the book will be of interest to all those working in the field.
Author: P.R.N. Childs
Publisher: Butterworth-Heinemann
ISBN: 0080524028
Category : Technology & Engineering
Languages : en
Pages : 420
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Book Description
Metal machining is the most widespread metal-shaping process in the mechanical manufacturing industry. World-wide investment in metal machining tools increases year on year - and the wealth of nations can be judged by it. This text - the most up-to-date in the field - provides in-depth discussion of the theory and application of metal machining at an advanced level. It begins with an overview of the development of metal machining and its role in the current industrial environment and continues with a discussion of the theory and practice of machining. The underlying mechanics are analysed in detail and there are extensive chapters examining applications through a discussion of simulation and process control. "Metal Machining: Theory and Applications" is essential reading for senior undergraduates and postgraduates specialising in cutting technology. It is also an invaluable reference tool for professional engineers. Professors Childs, Maekawa, Obikawa and Yamane are four of the leading authorities on metal machining and have worked together for many years.Of interest to all mechanical, manufacturing and materials engineersTheoretical and practical problems addressed
Author: Cheng Yong Wang
Publisher: Trans Tech Publications Ltd
ISBN: 3038135879
Category : Technology & Engineering
Languages : en
Pages : 780
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Book Description
Volume is indexed by Thomson Reuters CPCI-S (WoS). This special collection brings together the latest research results and technological advances concerning high-speed machining. It covers a wide range of topics in high-speed machining and high-performance machining-related fields ranging from the mechanisms of machining, modeling and simulation of machining process, machine tools, cutting tools, CAD/CAM, optimization, cooling and lubrication, testing, measuring, monitoring, controlling and industrial applications. The work will be of great interest to those working in the fields of processing, cutting-tool use, machine-tool use and CAD/CAE/CAM.
