Performance analysis of new external chip breaker for efficient machining of Inconel 718 and optimization of the cutting parameters

Yılmaz, Bahattin; Karabulut, Şener; Güllü, Abdulkadir

doi:10.1016/j.jmapro.2018.03.025

Cited by 73 publications

(34 citation statements)

References 26 publications

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“…In the Taguchi design [58], the decision parameter of the methodology is the signal-to-noise (S/N) ratio value. The optimal parameter combination is based on the maximum S/N ratio value [59][60][61]. The denominator of the S/N ratio value represents the disturbing effect of the uncontrollable noise factors of the process.…”

Section: Comparative Studymentioning

confidence: 99%

An experimental investigation for parametric appraisal of electrohydrodynamic-driven microfabrication approach using teaching and learning-based optimization

Das

Roy

Murmu

2020

J Braz. Soc. Mech. Sci. Eng.

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Electrohydrodynamic (EHD)-based microfabrication process is a novel high-resolution pattern generation technology for micro/nanoscale system fabrication. Achieving tiny droplets during deposition has been a critical issue for the further development of this new emerging technology. It is imperative to identify the proper fabrication parameters to get the desired resolution operation. In the current study, first, an experimental EHD microfabrication setup is developed, and then experiments are carried out to search for an operating condition, which can promote high-resolution droplet generation. The experiments are planned by design of experiment scheme. The influence of the operating control parameters such as nozzle to substrate gap, voltage and the supply rate of the material on deposited droplets diameter is investigated in the current work. Characterization study reveals that nozzle to substrate gap and supply rate have a positive effect on deposition behavior, whereas voltage has a negative association with the droplet resolution. For better control of the EHD process, a causal relationship is developed between process control and performance parameter. A metaheuristic search algorithm named teaching and learning-based optimization (TLBO) is employed to find out the optimal operating environment of the EHD process. The results are compared with the traditional robust parameter design approach, and the authors found that TLBO performs more effectively for resolution improvement in the EHD-driven microfabrication process. Moreover, the sequence in which the control parameters govern the fabrication process is identified and reported.

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Section: Comparative Studymentioning

confidence: 99%

An experimental investigation for parametric appraisal of electrohydrodynamic-driven microfabrication approach using teaching and learning-based optimization

Das

Roy

Murmu

2020

J Braz. Soc. Mech. Sci. Eng.

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show abstract

“…Nevertheless, these materials display difficult machinability characteristics [5,6] due to their low thermal diffusivity [2], high strain hardening [7], high chemical reactivity [8], carbide precipitation in grain boundaries [1] and high ductility [9]. Chief among these machining attributes, the high ductility of machined workpieces ordinarily leads to the formation of long continuous chips during the machining process, which negatively affects the safety, efficiency and continuity of the machining operation [10].…”

Section: Introductionmentioning

confidence: 99%

“…In addition, an appropriate design of a cutting tool is essential to achieve an effective chipping operation and to extend tool life [13,14]. However, chip evacuation is a recurrent problem that needs addressing with machining ductile and soft materials, especially with the formation of continuous chips [10,15,16]. Discontinuous and fragmented chips are easier to control as continuous chips can wrap around the workpiece and/or the cutting tool and clog the cutting zone, which negatively affects the cutting process.…”

Section: Introductionmentioning

confidence: 99%

“…Sci. 2019, 9, x FOR PEER REVIEW 2 of 14 the formation of continuous chips [10,15,16]. Discontinuous and fragmented chips are easier to control as continuous chips can wrap around the workpiece and/or the cutting tool and clog the cutting zone, which negatively affects the cutting process.…”

Section: Introductionmentioning

confidence: 99%

“…This results in a higher number of production stops and, therefore, in a dramatic increase of production time. Thus, the chip formation process and chip control using combined cryogenic and minimum quantity lubrication [19,20], applying cryogenic lubrication [7,21], high pressure coolant [2,11] ultrasonic-assisted vibration [15,17], optimization of the processing parameters [10,[22][23][24], and chip breakers [10,14,16] as well as their limitations [25], have been widely studied, both experimentally and by means of simulation. It is widely accepted that the contribution of chip breakers in enhancing the chip fragmentation process is significant.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

2019

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Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).

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Optimization of Cutting Parameters of Machinability Aspects During Dry Turning

Sharma

Singh

Singari

2020

Lecture Notes in Mechanical Engineering

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Performance analysis of new external chip breaker for efficient machining of Inconel 718 and optimization of the cutting parameters

Cited by 73 publications

References 26 publications

An experimental investigation for parametric appraisal of electrohydrodynamic-driven microfabrication approach using teaching and learning-based optimization

An experimental investigation for parametric appraisal of electrohydrodynamic-driven microfabrication approach using teaching and learning-based optimization

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

Optimization of Cutting Parameters of Machinability Aspects During Dry Turning

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