Nickel based superalloys have a wide range of applications due to high mechanical strength at high temperatures, fracture toughness and resistance to corrosion. However, because of their outstanding properties, it is considered as the difficult to machine materials. Inconel alloy X-750 is used extensively in rocket-engine thrust chambers. Airframe applications include thrust reversers and hot-air ducting systems along with large pressure vessels are formed from Inconel alloy X-750. Moreover, the comparative analysis of machinability aspect using coated carbide inserts is reported few. The current study explains the machinability investigation on Inconel alloy X-750 superalloys using coated carbides. To collect the experimental data, the L16 experimental design plan is used to experiment with a machining length of 40 mm. Four level of cutting speed (70,120,170,220 m/min), feed rate (0.1, 0.15, 0.2, 0.25 mm/rev) and cutting depth (0.3, 0.4, 0.5, 0.6 mm) are the cutting/machining parameters used. Cutting Forces, surface roughness, flank and crater wear are considered as target functions. With the application of response surface, coupled with desirability analysis, the optimal levels of the combination are determined. With determined optimal levels, tool life study has been carried out to compare the effectiveness of cutting inserts. Finally, the ranges for best cutting conditions are proposed for serial industrial production. © 2018 SAE International. All Rights Reserved.

Venkatesan K

Department of Design and Automation

School of Mechanical Engineering

Vellore Campus

Kannan V.V

Vellore Institute of Technology (VIT) is a private university located in&nbsp;Tamil Nadu, India. Founded in 1984, as Vellore Engineering College, the institution offers 20 undergraduate, 34 postgraduate, four integrated and four research programs. It has campuses in Vellore, Amravati, Bhopal and Chennai.

VIT is one of the top ranked private universities in India according to NIRF, THE and QS Rankings.&nbsp;Govt. of India has recognized&nbsp;VIT, Vellore as an&nbsp;Institution of Eminence. This has allowed VIT to take independent quality initiatives and move up in world ranking.

&nbsp;

&nbsp;

VIT University

A Comparative Study on Machinability Characteristics in Dry Machining of Inconel X-750 Alloy Using Coated Carbide Inserts

SAE Technical Paper Series

Inconel X-750, a nickel-chromium alloy, is found as a component in applications of the airframe and hot-air duct system. This paper presents the effect of different nanofluids (NF) concentration along with cutting speed and federate on Fz: cutting force, Ra: surface roughness and Vba: tool wear with the application of vegetable oil NF on turning of Alloy 750. The NF and vegetable oil taken for present investigation are nAl2O3 and coconut oil. Experimental is carried out using L9 orthogonal array and turned with PVD (AlTiN) coated carbide inserts. From the experimental research, 1.00% nAl2O3 nanofluids in coconut oil along with cutting speed of 87m/min and 0.14 mm/rev feed rate has proved the better machining performance to minimize the responses. Based on optical micrograph analysis, abrasion, adhesion and small BUE wear are three modes of wear mechanisms. Ribbon chips are produced with a different diameter, and curl diameter is increased with the increment of percentage concentration on turning of Inconel X-750. © 2019 The Authors. Published by Elsevier Ltd.

Fulltext

Procedia Manufacturing

Application of Taguchi-Response surface analysis to optimize the cutting parameters on turning of Inconel X-750 using Nanofluids suspended Al2O3 in coconut oil

Inconel 617 alloy is corrosion and oxidation resistant, nickel-based alloy and emanates under tough to turn material. Moreover, turning off this alloy under MQL need attention. In this context, this work aims to examine the machinability study under MQL on CNC turning of 617 alloys by AlTiN PVD carbide cutting inserts. As a methodology, the Taguchi L9 orthogonal array parameter design and response surface optimization has been employed. 1D and 3D plots have been used to analysis on the collected machining data based on fitted regression model. The statistical analysis revealed % concentration impacted for force, cutting velocity influenced for surface roughness and tool wear. From the optimization analysis, 0.25% Al2O3 Nano-fluid in coconut oil along with a cutting speed of 40 m/min and 0.14 mm/rev feed rate. Abrasion, adhesion and diffusion wear are identified as wear mechanisms. The diameter of produced helical and tubular chips are different, and at high % concentration, the curl diameter is found to be increased due to the decrease in lubricity and increase tool friction on turning of Inconel 617. © 2019 The Authors. Published by Elsevier Ltd.

Machinability study and multi-response optimization of cutting force, Surface roughness and tool wear on CNC turned Inconel 617 superalloy using Al2O3 Nanofluids in Coconut oil

Inconel 718, a high-temperature alloy, is a promising material for high-performance aerospace gas turbine engines components. However, the machining of the alloy is difficult owing to immense shear strength, rapid work hardening rate during turning, and less thermal conductivity. Hence, like ceramics and composites, the machining of this alloy is considered as difficult-to-turn materials. Laser assisted turning method has become a promising solution in recent years to lessen cutting stress when materials that are considered difficult-to-turn, such as Inconel 718 is employed. This study investigated the influence of input variables of laser assisted machining on the machinability aspect of the Inconel 718. The comparison of machining characteristics has been carried out to analyze the process benefits with the variation of laser machining variables. The laser assisted machining variables are cutting speeds of 60–150 m/min, feed rates of 0.05–0.125 mm/rev with a laser power between 1200 W and 1300 W. The various output characteristics such as force, roughness, tool life and geometrical characteristic of chip are investigated and compared with conventional machining without application of laser power. From experimental results, at a laser power of 1200 W, laser assisted turning outperforms conventional machining by 2.10 times lessening in cutting force, 46% reduction in surface roughness as well as 66% improvement in tool life when compared that of conventional machining. Compared to conventional machining, with the application of laser, the cutting speed of carbide tool has increased to a cutting condition of 150 m/min, 0.125 mm/rev. Microstructural analysis shows that no damage of the subsurface of the workpiece. © 2017

Journal of Advanced Research

The study on force, surface integrity, tool life and chip on laser assisted machining of inconel 718 using Nd:YAG laser source

High strength alloys such as nickel and titanium and advanced engineering materials such as ceramics, composites are being developed and widely used in aerospace, automotive, medical and nuclear industries due its inherent physical-mechanical properties. However conversion these new materials into engineering products are always associated with machining. The machinability characteristics such as higher cutting force, higher cutting temperature, poor surface integrity and shorter tool life associated with these materials posing many challenges to the researchers, and hence considered as difficult to cut materials. Conventional methods of machining these materials are found to be uneconomical. In recent days, many attempts have been made to improve the machinability of these materials more effectively via use of external energy assisted machining. Among the various external energy assisted machining methods, laser assisted machining (LAM) has received the attention of researchers in the metal cutting domain and a few research was carried during the recent years. This paper is aimed to review and summarize the potential use of LAM for difficult to cut materials, current progress, benefits and challenges in laser assisted machining. In addition an optimization frame work to study the effect of laser parameters and machining process parameters on machinability performance is not reported which is applicable to industrial processes It is concluded that further experimental modeling and empirical techniques are required to create a predictive based models that gives good agreement with reliable experiments, while explaining the effects of many parameters, for machining of these difficult-to-cut materials. © 2014 Published by Elsevier Ltd.

Procedia Engineering

Laser Assisted Machining of Difficult to Cut Materials: Research Opportunities and Future Directions - A Comprehensive Review

Journal of Manufacturing Processes

A comprehensive study on the effects of tool wear on surface roughness, dimensional integrity and residual stress in turning IN718 hard-to-machine alloy

The International Journal of Advanced Manufacturing Technology

A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

Experimental investigations of cutting parameters’ influence on cutting forces and surface roughness in turning of Inconel alloy X-750 with biodegradable vegetable oil

Journal	SAE Technical Paper Series
Publisher	SAE International
ISSN	01487191
Open Access	0