Controlling the material removal and roughness of Inconel 718 in laser machining

Ahmed, Naveed; Rafaqat, Madiha; Pervaiz, Salman; Umer, Usama; Alkhalefa, Hesham; Shar, Muhammad Ali; Mian, Syed Hammad

doi:10.1080/10426914.2019.1615082

Cited by 23 publications

(9 citation statements)

References 31 publications

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“…The occurrence of pits was seen after normalizing because pitting resistance reduced due to the exposure of the material to the atmosphere during cooling. Formation of long lines was observed in the annealed specimen along with some uniformity [ 37 , 38 ]. Smaller grain size was also observed in the annealed specimen due to the slow rate of cooling which leads to better compression in the material.…”

Section: Resultsmentioning

confidence: 99%

Multiobjective Optimization of Heat-Treated Copper Tool Electrode on EMM Process Using Artificial Bee Colony (ABC) Algorithm

et al. 2022

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Electrochemical micromachining (EMM) is a plausible method for manufacturing high accuracy and precision microscale components in a broad range of materials. EMM is commonly utilized to manufacture turbine blades for automobiles and aircrafts. In this present study, the EMM process was performed with a heat-treated copper tool electrode on aluminum 8011 alloy. The process parameters such as voltage, concentration of electrolyte, frequency, and duty factor were varied to analyze the effect of a heat-treated electrode on material removal rate (MRR), overcut, conicity, and circularity. It was observed that high MRR was obtained with lower overcut with an annealed electrode. The better conicity and circularity were obtained with a quenched electrode compared to other heat-treated and untreated tool electrodes. The artificial bee’s colony (ABC) algorithm was used to identify the optimum parameters and, finally, the confirmation test was carried out to evaluate the error difference on the machining process. The optimum combination of input process parameters found using TOPSIS and ABC algorithm for the EMM process are voltage (14 V), electrolyte concentration (30 g/L), frequency (60 Hz), and duty cycle (33%) for the annealed tool electrode and voltage (14 V), electrolyte concentration (20 g/L), frequency (70 Hz), and duty cycle (33%) for the quenched tool electrode. It was confirmed that 95% of accurate response values were proven under the optimum parameter combination.

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Section: Resultsmentioning

confidence: 99%

Multiobjective Optimization of Heat-Treated Copper Tool Electrode on EMM Process Using Artificial Bee Colony (ABC) Algorithm

et al. 2022

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“…Average surface roughness (Ra) of the engraved area was measured using Mitutoyo contact surface roughness tester (RJ‐201). Average roughness value (Ra) is the most common parameter to be considered in case of laser engraving of surfaces such as PMMA and Inconel . Average surface roughness gives an arithmetical mean of all the roughness values measured over the surface.…”

Section: Methodsmentioning

confidence: 99%

Experimental investigation of surface defects in low‐power CO₂ laser engraving of glass fiber‐reinforced polymer composite

Prakash

2019

Polymer Composites

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Glass fiber‐reinforced polymers (GFRP) possess excellent structural qualities making it superior to steels and various allied materials in terms of strength and durability. The machining of GFRPs is relatively tough and slow on conventional machining systems. Also, tool life can be significantly reduced while working on such advanced materials with conventional machining processes. Lasers have been proved as a very efficient machine tool for cutting of several newly developed engineering materials. Low‐power lasers can be effectively used for ablating a thin layer or inducing customized surface structures on the target surfaces. Polymer‐reinforced composites act as a multilayered material having significant difference in melting and vaporization temperature between glass fibers and polymer matrix. In this experimental work, GFRP was used as a substrate material and a low‐power CO2 laser was utilized for engraving over a GFRP surface at different amounts of energy deposition. Unidirectional GFRPs were engraved by laser‐engraving process at three different defocusing positions with the overall objective to investigate the surface quality and engraving depth. To study anisotropic effects of the material, laser engraving was performed into two different directions, that is, along the fiber and perpendicular to fiber. Surface roughness and machined depth were investigated as a function of fiber direction. It was observed that surface roughness as well as ablation depth of the laser‐engraved surface hugely depend on fiber direction. It was also found that defocusing results in adverse surface conditions unlike other materials. Based on the results obtained, simple regression‐based mathematical models have been developed to predict engraved depth as a function of energy deposition. The developed models were validated for engraving depth up to 300 μm.

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“…A mathematical model for HAZ of the bottom edge has been developed with the determination coefficient of model R 2 was 96.9% and 97.1% for untreated and HT plate, respectively, as shown in Eq. (7) and (8). The top and bottom cutting edges observed under a 3D microscope, and the image for one hole is shown in Figure 7 with greater magnification.…”

Section: Effect Of Process Parameters On Heat Affected Zonementioning

confidence: 99%

Laser Machining of Die Steel (EN-31): An Experimental Approach to Optimise Process Parameters using Response Surface Methodology

Patel¹,

Bhavsar²

2021

IJAME

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Experiments were performed based on response surface methodology (RSM) to investigate the process parameters effect on the features of hole geometry. Cutting speed (of 500-1000 mm/min), laser power (of 2000-4000 W), frequency (of 800-2000 Hz), duty cycle (of 75-95%), and gas pressure (of 0.05-0.15 bar) were considered as variable parameters. Deviation in the dimension of entrance and exit holes, heat affected zone (HAZ) on the upper & lower edge, and roughness were the output to analyse the cutting quality of 14 mm thick normal and heat-treated (HT) EN-31 die steel using 4 kW CO2 laser. For untreated plate, minimum taper angle was achieved with low cutting speed, higher laser power, and gas pressure. Higher cutting speed, low laser power, and higher gas pressure result in the minimum HAZ. For the HT plate, the mid-range of parameters results in the minimum taper angle and HAZ. An optimised model was developed, and the confirmatory test gives roughness up to 0.27 microns and it shows good agreement with the mathematical model. At the cross-section of holes, striation pattern, resolidified layer, and corner qualities were visually inspected. Surface damage near the cutting edge was observed using scanning electron microscopy.

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Controlling the material removal and roughness of Inconel 718 in laser machining

Cited by 23 publications

References 31 publications

Multiobjective Optimization of Heat-Treated Copper Tool Electrode on EMM Process Using Artificial Bee Colony (ABC) Algorithm

Multiobjective Optimization of Heat-Treated Copper Tool Electrode on EMM Process Using Artificial Bee Colony (ABC) Algorithm

Experimental investigation of surface defects in low‐power CO₂ laser engraving of glass fiber‐reinforced polymer composite

Laser Machining of Die Steel (EN-31): An Experimental Approach to Optimise Process Parameters using Response Surface Methodology

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Controlling the material removal and roughness of Inconel 718 in laser machining

Cited by 23 publications

References 31 publications

Multiobjective Optimization of Heat-Treated Copper Tool Electrode on EMM Process Using Artificial Bee Colony (ABC) Algorithm

Multiobjective Optimization of Heat-Treated Copper Tool Electrode on EMM Process Using Artificial Bee Colony (ABC) Algorithm

Experimental investigation of surface defects in low‐power CO2 laser engraving of glass fiber‐reinforced polymer composite

Laser Machining of Die Steel (EN-31): An Experimental Approach to Optimise Process Parameters using Response Surface Methodology

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Experimental investigation of surface defects in low‐power CO₂ laser engraving of glass fiber‐reinforced polymer composite