Experimental investigation on micro drilling of Inconel 718 super alloy

Venkatesan, T. R.; Jerald, Jason; Pilligrin, J. Cyril; Asokan, P.

doi:10.1504/ijmmm.2018.089470

Cited by 5 publications

(3 citation statements)

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“…The wandering of the tool occurs at low speeds which decrease with increase in rotational speed. Similar results of tool wandering and decrease in overcut have been reported in Venkatesan [25]. However, some literatures have reported an increase in the wandering motion of the tool and overcut at spindle speeds of 20000 rpm and higher.…”

Section: Analysis Of Overcutsupporting

confidence: 82%

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Assessment of surface integrity and hole quality in graphene-based NMQL Micro-drilling of ceramic-coated Nimonic 90 for gas turbine applications

Patil

Sawant³

2023

Eng. Res. Express

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Nickel-based superalloys have superior strength properties at higher temperature ranges and thus have become increasingly important in manufacturing gas turbine components for aerospace industry. However, the desire for a larger thrust-weight ratio has raised the typical operating temperature in a gas turbine; thus, thermal barrier coatings are essential. The present work compares the micro-drilling performance of ceramic-coated Nimonic 90 nickel superalloy under dry, flood and 0.5% graphene-based NMQL conditions. The biodegradable acid oil was used as a base oil, and the assessment comprised surface integrity in terms of surface roughness inside the hole and micro-crack formation and hole quality based on the diametrical overcut and taper ratio. Spindle speed (1000, 2000 and 3000 rpm) and feed rate (3, 6, and 9 μm/rev) were changed in three levels, and Taguchi L9 array was applied for the design and analysis of the experiments. Ti-Al-N coated tungsten carbide drill of diameter 700 μm was used, and Analysis of variance (ANOVA) revealed that spindle speed was the utmost important parameter impacting surface roughness, while speed and feed rate both influenced overcut and taper ratio. 0.5% Graphene-based NMQL lubrication condition significantly diminished the surface roughness by 52.67%, overcut by 46.86% and the taper ratio by 48.87% as compared to dry condition. Furthermore, in the NMQL condition, micro-crack development and ceramic layer damage were minimized, resulting in better surface integrity. In addition, burr development was minimized at the hole periphery, and tool wandering was not seen in the NMQL condition. Hence the hole quality was superior in NMQL conditions as compared to the dry and flood lubrication.

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Section: Analysis Of Overcutsupporting

confidence: 82%

“…It was concluded that temperature at the machining zone increases with spindle speed and feed. In addition, hole quality was superior at low-temperature conditions [25]. Tool life and hole quality were compared by using an uncoated tungsten carbide drill and TiAlN-coated drill tool in the case of Inconel X 750.…”

Section: Introductionmentioning

confidence: 99%

Assessment of surface integrity and hole quality in graphene-based NMQL Micro-drilling of ceramic-coated Nimonic 90 for gas turbine applications

Patil

Sawant³

2023

Eng. Res. Express

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“…Notably, temperature increased with higher speed and feed, while MRR improved with larger tool diameter, feed rate, and spindle speed. As feed rate increased, machining time decreased, but cutting force increased with higher tool diameter, feed rate, and spindle speed [8]. Spindle speed, feed rate, and forces were correlated to surface integrity in the context of micro drilling Incoloy 825 under flood cooling.…”

Section: Introductionmentioning

confidence: 95%

Assessing the torque and thrust forces in micro-drilling of thermal barrier coated nickel superalloys

Patil,

Kamble

2023

Eng. Res. Express

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Nickel superalloys are crucial materials for aerospace applications, offering exceptional performance at high temperatures. Key components in aircraft engines, such as turbine blades, guiding vanes, afterburners, and casings, require the intricate process of micro-drilling to enable effusion cooling. However, when dealing with nickel-based superalloys, tool breakage during micro-drilling is a substantial drawback. This study investigates the cutting forces acting at the tool-workpiece interface during the micro-drilling of thermal barrier-coated Nimonic 90. The micro-drilling was conducted under three lubrication conditions: dry, flood, and 0.5% Graphene-based NMQL, utilizing a 700 μm diameter TiAlN-coated tungsten carbide drill. Experiments were performed at spindle speeds of 1000, 2000, and 3000 rpm, with a constant feed rate of 3 μm/rev. Results revealed that under dry conditions, the micro-drill failed after drilling just 16, 18, and 15 holes at spindle speeds of 1000, 2000, and 3000 rpm, respectively. In contrast, no failures occurred under flood and 0.5% Graphene-based NMQL lubrication conditions, likely due to improved heat dissipation, resulting in reduced thrust forces and torque acting on the micro-drill. Thrust force and torque values were measured using a Kistler 3-component mini dynamometer, with maximum values of 26 N and 0.31 N-m at 1000 rpm under dry lubrication conditions. These values decreased to 24 N and 0.25 N-m and 22 N and 0.19 N-m at spindle speeds of 2000 and 3000 rpm, respectively. NMQL lubrication conditions consistently exhibited lower thrust force and torque values compared to dry and flood conditions, with the lowest recorded values (12.5 N and 0.06 N-m) at 3000 rpm in the NMQL lubrication condition. The NMQL condition facilitated for efficient and better drilling operation due to the rolling effect produced by the graphene nanoparticles.

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Study of cutting forces and surface integrity in micro drilling of a Ni-based superalloy

Azim

Gangopadhyay

Mahapatra

et al. 2019

Journal of Manufacturing Processes

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Experimental investigation on micro drilling of Inconel 718 super alloy

Cited by 5 publications

References 0 publications

Assessment of surface integrity and hole quality in graphene-based NMQL Micro-drilling of ceramic-coated Nimonic 90 for gas turbine applications

Assessment of surface integrity and hole quality in graphene-based NMQL Micro-drilling of ceramic-coated Nimonic 90 for gas turbine applications

Assessing the torque and thrust forces in micro-drilling of thermal barrier coated nickel superalloys

Study of cutting forces and surface integrity in micro drilling of a Ni-based superalloy

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