Machinability Investigations of Inconel-800 Super Alloy under Sustainable Cooling Conditions

Gupta, Munish Kumar; Pruncu, Catalin I.; Mia, Mozammel; Singh, Gurraj; Singh, Sunpreet; Prakash, Chander; Sood, Pardeep Kumar; Gill, Harjot Singh

doi:10.3390/ma11112088

Cited by 74 publications

(18 citation statements)

References 39 publications

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“…Nowadays, a great opportunity has arisen to produce robust parts for aerospace and the turbine sector with advanced performances (high mechanical strength at elevated temperatures and high resistance against corrosion) made of nickel-based superalloys (e.g., Inconel-800) [1] and titanium-based superalloys (e.g., Ti-6Al-4V) [2]. However, during machining processes, they raise challenges because of high toughness, low heat transfer coefficient, and very poor work hardening [3].…”

Section: Introductionmentioning

confidence: 99%

Parametric optimization and process capability analysis for machining of nickel-based superalloy

Gupta

Mia

Pruncu

et al. 2019

Int J Adv Manuf Technol

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111

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The manufacturing of parts from nickel-based superalloy, such as Inconel-800 alloy, represents a challenging task for industrial sites. Their performances can be enhanced by using a smart cutting fluid approach considered a sustainable alternative. Further, to innovate the cooling strategy, the researchers proposed an improved strategy based on the minimum quantity lubrication (MQL). It has an advantage over flood cooling because it allows better control of its parameters (i.e., compressed air, cutting fluid). In this study, the machinability of superalloy Inconel-800 has been investigated by performing different turning tests under MQL conditions, where no previous data are available. To reduce the numerous numbers of tests, a target objective was applied. This was used in combination with the response surface methodology (RSM) while assuming the cutting force input (F c), potential of tool wear (VB max), surface roughness (Ra), and the length of tool-chip contact (L) as responses. Thereafter, the analysis of variance (ANOVA) strategy was embedded to detect the significance of the proposed model and to understand the influence of each process parameter. To optimize other input parameters (i.e., cutting speed of machining, feed rate, and the side cutting edge angle (cutting tool angle)), two advanced optimization algorithms were introduced (i.e., particle swarm optimization (PSO) along with the teaching learning-based optimization (TLBO) approach). Both algorithms proved to be highly effective for predicting the machining responses, with the PSO being concluded as the best amongst the two. Also, a comparison amongst the cooling methods was made, and MQL was found to be a better cooling technique when compared to the dry and the flood cooling.

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Section: Introductionmentioning

confidence: 99%

Parametric optimization and process capability analysis for machining of nickel-based superalloy

Gupta

Mia

Pruncu

et al. 2019

Int J Adv Manuf Technol

Self Cite

111

View full text Add to dashboard Cite

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“…A TiN/TiCN/TiAlN multi-coated tool is the most suitable for the high-speed milling of AISI 4340 due to the lower cutting force, lower cutting temperature, and high diffusion resistance of the material. Gupta et al [41] discussed the features of two innovative techniques for machining an Inconel-800 superalloy by plain turning while considering some critical parameters, reducing the amount of cutting fluid while using sustainable methods. Near dry machining (NDM) will be possible and will solve the problem of chemical components in the fluids being harmful to human health.…”

Section: Dimensions Of the Sustainability Metrics For Machining Procementioning

confidence: 99%

An Approach to Sustainable Metrics Definition and Evaluation for Green Manufacturing in Material Removal Processes

Ayabaca

Vila

2020

Materials

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Material removal technologies should be thoroughly analyzed not only to optimize operations but also to minimize the different waste emissions and obtain cleaner production centers. The study of environmental sustainability in manufacturing processes, which is rapidly gaining importance, requires activity modeling with material and resource inputs and outputs and, most importantly, the definition of a balanced scorecard with suitable indicators for different levels, including the operational level. This paper proposes a metrics deployment approach for the different stages of the product life cycle, including a conceptual framework of high-level indicators and the definition of machining process indicators from different perspectives. This set of metrics enables methodological measurement and analysis and integrates the results into aggregated indicators that can be considered for continuous improvement strategies. This approach was validated by five case studies of experimental testing of the sustainability indicators in material removal operations. The results helped to confirm or modify the approach and to adjust the parameter definitions to optimize the initial sustainability objectives.

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“…Gupta et al [22] discussed the features of two innovative techniques for machining an Inconel 800 superalloy by plain turning, while also considering some critical parameters, such as the cutting force, average surface roughness (R a ), tool wear rate and chip morphology. Their research findings highlighted the robustness of the near-dry machining process over the dry machining routine, as well as demonstrating its great potential to resolve the heat transfer concerns associated with this manufacturing method.…”

Section: Study Materials and Applicationsmentioning

confidence: 99%

Sustainability Analysis of AISI 1018 Turning Operations under Surface Integrity Criteria

et al. 2019

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While the world is moving towards achieving sustainable development goals for responsible production and consumption, there is a need for metrics deployment for lower practical levels. From a manufacturing perspective, definitions of sustainability indicators are required for industrial processes and operations. These metrics encourage the evaluation of manufactured parts and whether they meet the quality requirements in both a qualitative and quantitative way. The present contribution proposes a framework for defining a structured set of metrics customizable for operations in different manufacturing technologies. In order to validate the proposal, an experimental data analysis of turning operations was completed and the surface integrity was defined as the control feature. The selected material was AISI 1018 and the main process parameters were controlled in order to identify their influence—not only in the final mechanical quality of the part, but also in the sustainability indicators. To achieve this goal, a set of experiments was performed wherein some of the fundamental machining parameter values were fixed, while other key parameters were modified. The results obtained helped to determine the criteria for predicting the quality of the turning operation when the effects are not readily evident in visual or dimensional inspections, as well as in evaluating the environmental impact that guarantees optimal part manufacturing.

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Machinability Investigations of Inconel-800 Super Alloy under Sustainable Cooling Conditions

Cited by 74 publications

References 39 publications

Parametric optimization and process capability analysis for machining of nickel-based superalloy

Parametric optimization and process capability analysis for machining of nickel-based superalloy

An Approach to Sustainable Metrics Definition and Evaluation for Green Manufacturing in Material Removal Processes

Sustainability Analysis of AISI 1018 Turning Operations under Surface Integrity Criteria

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