A Study on Optimal Machining Conditions and Energy Efficiency in Plasma Assisted Machining of Ti-6Al-4V

Lee, Young-Hun; Lee, Choon-Man

doi:10.3390/ma12162590

Cited by 15 publications

(5 citation statements)

References 28 publications

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“…The workpiece and torch distance are maintained at a fixed distance. Additionally, transfer type is more challenging to utilize because it only functions on conductive materials [7,8,9]. The thermal power can be estimated as follows if it is assumed that the heat spread is uniform:…”

Section: Induction Heatingmentioning

confidence: 99%

“…For Ti-6Al-4V the force on tool was reduced by 60.2% and Ra by 0.376 µm to 0.111 µm. When compared to conventional heating, plasma assisted machining (PAM) resulted in a surface roughness improvement of 70.47%, and its specific cutting energy was 32.9 N/mm 2 [8].…”

Section: Plasma Assisted Machining Processmentioning

confidence: 99%

“…Surface Roughness for AISI1045 steel was improved by 5% as compared to LAM and the difference between the cutting forces was about 8-15 % when compared PAM with LAM [9]. Wheather the efficiency of PAM was increased by 60.26% when compared to traditional machning for Ti-6Al-4V [8]. As due to high degree of heat concentration the tool life is increases and material removal rate is also increases.…”

Section: Multi-tool Machining Processmentioning

confidence: 99%

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A Novel Approach of Heat Assisted Parallel Turning Process

Mishra,

Kalidasan,

Yadav

2023

KEM

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Hard materials are widely used in industry due to qualities such as strong fatigue strength and the ability to maintain strength at a high temperature. Still forming certain raw materials into the appropriate shapes is the challenge in subtractive manufacturing industries and these materials are categorized as hard to machine material. To solve this problem Heat Assisted Machining (HAM) is an emerging and most dominating method, which requires an external heat source subjected to the workpiece either before or during the machining to increase the ductility. As a result, the workpiece yield and shear strength are reduced. This is an advanced technique to enhance the tool’s life, and productivity. The present paper provides in-depth knowledge of thermal assisted machining process where various heat sources are used like laser, plasma, LPG, Induction heating and etc. The comparison analysis between various heat sources is made and their impact on various parameters like tool wear, material removal rate, surface roughness, stability and etc. were illustrated and provide the novel approach for selecting the correct heat-assisted technique which is used for turning process in order to increase the machining process.

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Section: Induction Heatingmentioning

confidence: 99%

Section: Plasma Assisted Machining Processmentioning

confidence: 99%

Section: Multi-tool Machining Processmentioning

confidence: 99%

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A Novel Approach of Heat Assisted Parallel Turning Process

Mishra,

Kalidasan,

Yadav

2023

KEM

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“…To overcome the issues associated with conventional machining of hard-to-cut materials, advanced and hybrid machining processes have been researched. These include Cryogenic cooling [3], Minimum quantity lubrication (MQL) [4], Vibration-assisted machining (VAM) [5], modi cation of cutting tool surface with different micro-textures using femtosecond laser [6], and various Thermal-assisted machining (TAM) processes like Plasma-assisted machining (PAM) [7], Induction-assisted machining (IAM) [8], and Laser-assisted machining (LAM) [9][10][11][12][13][14][15][16][17][18][19][20]. In recent years, LAM has become the preferred alternative due to the favorable properties of laser beams, such as good focusing ability, localized heating, and ease of automation.…”

Section: Introductionmentioning

confidence: 99%

Developing Laser-Assisted Machining Process for Nickel Based Superalloy IN625 Using Experimental and Statistical Analysis

Rao,

Tak,

Rao

et al. 2023

Lasers Manuf. Mater. Process.

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This study evaluated the optimization of process parameters in laser-assisted turning of IN625 nickelbased superalloy. IN625 is renowned for its high-temperature strength and work-hardening properties, making it challenging to machine using traditional techniques. In order to overcome this di culty, a laserassisted machining setup was employed that combined a conventional lathe with a 6 kW bre-coupled diode laser and dynamometer. The Box-Behnken design of experiments strategy based on Response Surface Methodology was used to optimize the machining conditions. The interplay between various machining properties, such as cutting forces, ank wear, and surface roughness, and machining process parameters, such as laser power, spindle speed, feed rate, and depth of cut, was investigated. The optimal parameters for laser-assisted turning of IN625 alloy included a laser power of 625 W, speed of 45 m/min, and feed of 0.15 mm/rev. These parameters led to reductions in cutting forces of 20% (F x ), 17% (F y ), 30% (F z ), as well as maximum ank wear and surface roughness of 18% and 16%, respectively. This study provides an effective strategy for optimizing the machining of IN625 alloys, which is di cult to machine by traditional techniques due to its high-temperature strength and work-hardening properties.

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“…In another study of Kim et al [ 17 ], induction assisted milling of Inconel 718 has been reported and optimized process parameters are proposed. For the same analogy, plasma has been used as an assisting source of energy to machine Ti 6Al 4V, and the process is termed as plasma-assisted machining [ 18 ]. In this way, by the use of additional source of energy to soften the localized area ahead of the cutting tool, the cutting forces can be reduced and tool life can be enhanced by minimizing the frequency of tool failure.…”

Section: Introductionmentioning

confidence: 99%

Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin

et al. 2020

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Titanium-aluminium-vanadium (Ti 6Al 4V) alloys, nickel alloys (Inconel 718), and duraluminum alloys (AA 2000 series) are widely used materials in numerous engineering applications wherein machined features are required to having good surface finish. In this research, micro-impressions of 12 µm depth are milled on these materials though laser milling. Response surface methodology based design of experiment is followed resulting in 54 experiments per work material. Five laser parameters are considered naming lamp current intensity (I), pulse frequency (f), scanning speed (V), layer thickness (LT), and track displacement (TD). Process performance is evaluated and compared in terms of surface roughness through several statistical and microscopic analysis. The significance, strength, and direction of each of the five laser parametric effects are deeply investigated for the said alloys. Optimized laser parameters are proposed to achieve minimum surface roughness. For the optimized combination of laser parameters to achieve minimum surface roughness (Ra) in the titanium alloy, the said alloy consists of I = 85%, f = 20 kHz, V = 250 mm/s, TD = 11 µm, and LT = 3 µm. Similarly, optimized parameters for nickel alloy are as follows: I = 85%, f = 20 kHz, V = 256 mm/s, TD = 8 µm, and LT = 1 µm. Minimum roughness (Ra) on the surface of aluminum alloys can be achieved under the following optimized parameters: I = 75%, f = 20 kHz, V = 200 mm/s, TD = 12 µm, and LT = 3 µm. Micro-impressions produced under optimized parameters have surface roughness of 0.56 µm, 2.46 µm, and 0.54 µm on titanium alloy, nickel alloy, and duralumin, respectively. Some engineering applications need to have high surface roughness (e.g., in case of biomedical implants) or some desired level of roughness. Therefore, validated statistical models are presented to estimate the desired level of roughness against any laser parametric settings.

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A Study on Optimal Machining Conditions and Energy Efficiency in Plasma Assisted Machining of Ti-6Al-4V

Cited by 15 publications

References 28 publications

A Novel Approach of Heat Assisted Parallel Turning Process

A Novel Approach of Heat Assisted Parallel Turning Process

Developing Laser-Assisted Machining Process for Nickel Based Superalloy IN625 Using Experimental and Statistical Analysis

Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin

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