Machining induced surface integrity behavior of nickel-based superalloy: Effect of lubricating environments

Singh, Ramandeep; Sharma, Varun

doi:10.1016/j.jmatprotec.2022.117701

Cited by 30 publications

(5 citation statements)

References 57 publications

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“…Thus, BBD is selected in Cutting speed was the only significant parameter for tool wear, while feed rate was the most significant parameter for surface roughness. Monaca et al [33] Inconel 718 Cutting speed, rake angle and shape edge radius Cutting force and energy One factor at a time Small-scale behavior reduces the cutting force and energy by 25%-30% Singh and Sharma [34] Hastelloy the present work. The experiments are conducted within the polynomial region, and the design is rotatable (or near rotatable) [37].…”

Section: Planning Of Experimentsmentioning

confidence: 54%

Investigation of parameters and morphology of coated WC tool while machining X-750 using NSGA-II

Bohat

Sharma

2023

Eng. Res. Express

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Nickel-based superalloys have numerous applications in automobile, aerospace, turbine blades, nuclear, oil refinery etc., due to their excellent properties like strength, wear resistance, corrosion resistance and higher creep strength. Because of these properties, modern manufacturing industries need help with the machining of nickel-based superalloys, i.e. hard-to-machine materials. In the present research, Ni-based X-750 alloy is machined with turning operation by a conventional lathe machine using a TiAlN PVD coated tungsten carbide tool at different rotational speed (TRS), depth of cut (DoC) and feed (F) values as input parameters whereas material removal rate (MRR) and tool wear (TW) are the responses of the study. The design of experiments (DoE) is prepared by response surface methodology-based Box-Behnken Design. Analysis of variance (ANOVA) was applied to investigate the percentage contribution of each machining parameter on responses. Non-dominated Sorting Genetic Algorithm-II (NSGA-II) simultaneously optimizes the developed empirical models of MRR and TW. The predicted solutions suggested by NSGA-II are the best solution, and confirmation experiments are conducted on randomly selected parametric settings from these solutions. The optimized set presented by NSGA-II is TRS: 900RPM; DoC: 0.06mm; F: 0.1mm/rev, and the maximum relative error in the case of MRR and TW is in the permissible limit. Scanning electron microscopy (SEM) and Energy dispersive spectroscopy (EDS) are used to investigate the morphology of tool insert before and after machining at optimized value TRS: 900 RPM; DoC: 0.1 mm; F: 0.06 mm/rev, and it shows the wear marks on the tool, and the Energy dispersive spectroscopy confirms the presence of coating and WC. SEM is used to investigate the morphology of chips formed at different optimized parametric settings.

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Section: Planning Of Experimentsmentioning

confidence: 54%

Investigation of parameters and morphology of coated WC tool while machining X-750 using NSGA-II

Bohat

Sharma

2023

Eng. Res. Express

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“…UVMQL compared to dry cutting. Among them, UVMQL produces finer and more uniform oil droplets than MQL, with greater penetration in the cutting zone, forming a more effective oil film lubrication layer and less cutting force [24]. The last four cooling and lubrication conditions all contribute to chip removal, effectively facilitating the penetration of cutting fluid and alleviating tool sticking (Fig.…”

Section: Cutting Force and Temperaturementioning

confidence: 99%

“…Additionally, the cross-section surface of the chip reveals serrated features for all five cooling and lubrication conditions. Under dry cutting and HPAC conditions, the workpiece material exhibits significant plastic deformation on the shear surface, resulting in pronounced serration on the chip surface, which can be attributed to elevated temperatures within the cutting zone [24]. The application of cutting fluid lubrication reduces chip serration.…”

Section: Chip Morphologymentioning

confidence: 99%

“…developed a cutting fluid spray system based on ultrasonic atomization and investigated the influence of system parameters and cutting fluid concentration on the cutting performance of Ti-6Al-4V alloys. The influence of different environments, including dry, flood cooling, MQL, and UVMQL, on the machinability of Hastelloy C-276 alloy was investigated by Ramandeep et al [24]. Their findings revealed that the utilization of UVMQL technology can significantly enhance the workpiece surface roughness, thereby improving the service life and performance.…”

Section: Introductionmentioning

confidence: 99%

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A novel cooling and lubrication approach: Device development and machining performance evaluation of ultrasonic vibration–assisted MQL

Zhang,

Wu,

Zhao

et al. 2024

Int J Adv Manuf Technol

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Minimum quantity lubrication (MQL) as a sustainable technology has gained popularity in addressing the conflict between environmental protection and the machining requirements during cutting processes. However, conventional MQL systems employ pneumatic atomization, resulting in the generation of oil droplets with large particle sizes and uneven distribution, eventually leading to the inadequate lubrication performance of the MQL jet. In this case, the present study employed a combination of ultrasonic atomization and MQL technique to propose a novel cooling and lubrication approach and fabricate the ultrasonic vibration-assisted MQL (UVMQL) device. Geometric parameters of the ultrasonic vibrator of this device were designed and optimized using the theoretical design and finite element simulation techniques. Additionally, the impedance and amplitude detected to evaluate the performance of the UVMQL device.Subsequently, the comparative experiments were carried out under five cooling and lubrication conditions in machining of ultra-high strength steels: dry cutting, wet cutting, high-pressure air cooling, MQL and UVMQL. Then, the machining performance of the UVMQL was discussed, in terms of cutting forces, cutting temperature, surface roughness, surface topography and chips. Results demonstrate that in comparison to MQL, UVMQL has a lower cutting force by 5.3N, leading to the formation of a more effective oil film lubrication layer. Due to the excellent penetration of fine oil droplets, UVMQL possesses a slightly higher cutting temperature than that of wet cutting by 43℃, whereas results in optimal surface roughness value and surface topography of the workpiece. Additionally, under UVMQL condition, the length of chip bonding zone is reduced by 39.8%, and the saw-tooth height of chip is decreased by 35.9% compared to dry cutting.

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“…The only way to reduce this phenomenon is to use cutting fluid [38][39][40]. Numerous studies [26,41,42] have shown that machining these materials whilst dry does not work with carbide tools. This is because dry machining lacks a cooling and lubricating medium to dissipate the high cutting temperatures from the zone and to lubricate the contact surface between the tool and the workpiece.…”

Section: Introductionmentioning

confidence: 99%

Effects of Oil Concentration in Flood Cooling on Cutting Force, Tool Wear and Surface Roughness in GTD-111 Nickel-Based Superalloy Slot Milling

Kónya,

Kovács

2024

JMMP

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Cooling–lubricating processes have a big impact on cutting force, tool wear, and the quality of the machined surface, especially for hard-to-machine superalloys, so the choice of the right cooling–lubricating method is of great importance. Nickel-based superalloys are among the most difficult materials to machine due to their high hot strength, work hardening, and extremely low thermal conductivity. Previous research has shown that flood cooling results in the least tool wear and cutting force among different cooling–lubricating methods. Thus, the effects of the flood oil concentration (3%; 6%; 9%; 12%; and 15%) on the above-mentioned factors were investigated during the slot milling of the GTD-111 nickel-based superalloy. The cutting force was measured during machining with a Kistler three-component dynamometer, and then after cutting the tool wear and the surface roughness on the bottom surface of the milled slots were measured with a confocal microscope and tactile roughness tester. The results show that at a 12% oil concentration, the tool load and tool wear are the lowest; even at an oil concentration of 15%, a slight increase is observed in both factors. Essentially, a higher oil concentration reduces friction between the tool and the workpiece contact surface, resulting in reduced tool wear and cutting force. Furthermore, due to less friction, the heat generation in the cutting zone is also reduced, resulting in a lower heat load on the tool, which increases tool life. It is interesting to note that the 6% oil concentration had the highest cutting force and tool wear, and strong vibration was heard during machining, which is also reflected in the force signal. The change in oil concentration did not effect the surface roughness.

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Machining induced surface integrity behavior of nickel-based superalloy: Effect of lubricating environments

Cited by 30 publications

References 57 publications

Investigation of parameters and morphology of coated WC tool while machining X-750 using NSGA-II

Investigation of parameters and morphology of coated WC tool while machining X-750 using NSGA-II

A novel cooling and lubrication approach: Device development and machining performance evaluation of ultrasonic vibration–assisted MQL

Effects of Oil Concentration in Flood Cooling on Cutting Force, Tool Wear and Surface Roughness in GTD-111 Nickel-Based Superalloy Slot Milling

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