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1.
《Wear》1996,193(1):16-24
Wear surfaces of the cutting tools are analyzed to study the wear mechanism of cemented carbide tools in turning in Inconel 718 superalloys. SEM and EPMA analyses indicated that the wear of carbide tools during high speed turning condition (V = 35 m min−1) was caused by diffusion of elements (Ni or Fe) in workpiece into tool's binder (Co) by a grain boundary diffusion mechanism. This action weakened the bonding strength between carbide particles (WC, TiC, TaC) and the binder (Co). The carbide particles were then detached out of the cemented carbide tool by high flow stresses. The proposed grain boundary diffusion mechanism is also confirmed by theoretical analysis. 相似文献
2.
J. S. Senthilkumaar P. Selvarani R. M. Arunachalam 《The International Journal of Advanced Manufacturing Technology》2012,58(9-12):885-894
The heat-resistant super alloy material like Inconel 718 machining is an inevitable and challenging task even in modern manufacturing processes. This paper describes the genetic algorithm coupled with artificial neural network (ANN) as an intelligent optimization technique for machining parameters optimization of Inconel 718. The machining experiments were conducted based on the design of experiments full-factorial type by varying the cutting speed, feed, and depth of cut as machining parameters against the responses of flank wear and surface roughness. The combined effects of cutting speed, feed, and depth of cut on the performance measures of surface roughness and flank wear were investigated by the analysis of variance. Using these experimental data, the mathematical model and ANN model were developed for constraints and fitness function evaluation in the intelligent optimization process. The optimization results were plotted as Pareto optimal front. Optimal machining parameters were obtained from the Pareto front graph. The confirmation experiments were conducted for the optimal machining parameters, and the betterment has been proved. 相似文献
3.
Jinming Zhou Volodymyr Bushlya Pajazit Avdovic Jan Eric St?hl 《The International Journal of Advanced Manufacturing Technology》2012,58(1-4):141-151
Inconel 718 is known to be among the most difficult-to-machine materials due to its special properties which cause the short tool life and severe surface damages. The properties, which are responsible for poor machinability, include rapid work hardening during machining; tendency to weld with the tool material at high temperature generated during machining; the tendency to form a built-up edge during machining; and the presence of hard carbides, such as titanium carbide and niobium carbide, in their microstructure. Conventional method of machining Inconel 718 with cemented carbide tool restricts the cutting speed to a maximum 30?m/min due to the lower hot hardness of carbide tool, high temperature strength and low thermal conductivity of Inconel 718. The introduction of new coated carbide tools has increased cutting speed to 100?m/min; nevertheless, the time required to machine this alloy is still considerably high. High speed machining using advanced tool material, such as CBN, is one possible alternative for improving the productivity of this material due to its higher hot hardness in comparison with carbide tool. This paper specifically deals with surface quality generated under high speed finishing turning conditions on age-hardened Inconel 718 with focus on surface roughness, metallographic analysis of surface layer and surface damages produced by machining. Both coated and uncoated CBN tools were used in the tests, and a comparison between surfaces generated by both tools was also discussed. 相似文献
4.
Wojciech Zębala Bogdan Słodki 《The International Journal of Advanced Manufacturing Technology》2013,65(5-8):881-893
The paper presents research work concerning difficult-to-cut materials turning and chipbreakers reliability in local operating features. Inconel 718 alloy was used as a sample material and two different chipbreakers were tested. The aim of the research was to check the efficiency of chipbreakers in the area of applications recommended by tool manufacturers. As a result, the algorithm for cutting data selection and correction which combines experiments and simulation processes concerning chip breakage effectiveness was built. To estimate chip forms in tests, the visual system equipped with a high-speed camera was used. The cutting forces measuring system provided information for verification of simulation results. The simulation based on the FEM was applied to estimate chip groove filling. Distributions of temperature and stresses on the tool rake face in the function of distance from the cutting edge were calculated. The paper gives recommendations for cutting data correction to achieve acceptable chip forms. 相似文献
5.
D. G. Thakur B. Ramamoorthy L. Vijayaraghavan 《The International Journal of Advanced Manufacturing Technology》2009,41(5-6):421-429
This article presents an approach based on wavelet correlation modelling for health state monitoring of fluid dynamic bearings in brushless DC motors. This approach involves two stages: (1) extracting of features from the motor-stator current signatures by analysing discrete wavelet transform coefficients; and (2) building of the simplest correlation model between the extracted features and the bearing wear using a multivariable regression technique. The correlation model can be used to detect and predict the bearing wear of brushless DC motors. Experiments were carried out using brushless DC motors with fluid dynamic bearings to verify the proficiency of this approach. Good agreement between the prediction result and the real motor health condition demonstrated the viability of the approach for bearing prognostic applications. The correlation equations obtained have acceptable detectability and accuracy based on a desired 95% level of confidence. 相似文献
6.
Ching-Been Yang Cang-Ge Lin Hsiu-Lu Chiang Chein-Chung Chen 《The International Journal of Advanced Manufacturing Technology》2017,93(9-12):3075-3084
Inconel 718 is widely used in high-temperature environments, high-performance aircraft, and hypersonic missile weapon systems; however, it is very difficult to machine using conventional techniques. This study employed an L9 Taguchi orthogonal array for the analysis of wire electrical discharge machining parameters when used for the machining of Inconel 718. Our aim was to determine the optimal combination of parameters to minimize surface roughness while maximizing the material removal rate. The Taguchi method is widely applied in mechanical engineering with the aim of identifying the optimal combination of processing parameters as they pertain to single quality characteristics. Unfortunately, Taguchi analysis often leads to contradictory results when seeking to rectify multiple objectives. To resolve this issue, this study implemented gray relational analysis in conjunction with Taguchi method to obtain the optimal combination of parameters to deal specifically with multiple quality objectives. For the dual objectives of surface roughness and material removal rate, the optimal combination of parameters derived using gray relational analysis resulted in a mean surface roughness of 2.75 μm. In L9 orthogonal array experiments, run 1 produced the best gray relational grade with mean surface roughness of 2.80 μm, representing an improvement of 1.8%. The material removal rate achieved after the application of gray relational analysis was 0.00190 g/s, whereas the L9 experiment achieved a material removal rate of 0.00123 g/s, representing an improvement of 54.5%. 相似文献
7.
This paper focuses on the analysis of tool wear mechanisms in finishing turning of Inconel 718, one of the most used Ni alloys, both in wet and dry cutting. Cemented carbides, ceramics and CBN tools are suitable for machining Ni alloys; coated carbide tools are competitive for machining operations of Ni alloys and widely used in industry. Commercial coated carbide tools (multilayer coating TiAl/TiAlN recommended for machining Ni alloys) were studied in this work. The feasibility of two inserts tested for dry cutting of Inconel 718 has been shown in the work. Experimental test were performed in order to analyze wear patterns evolution. It was found great influence of side cutting edge angle in tool wear mode. 相似文献
8.
This paper presents the results of an experimental investigation on the wear mechanisms of uncoated tungsten carbide (WC) and coated tools (single-layer (TiAlN) PVD, and triple-layer (TiCN/Al2O3/TiN) CVD) in oblique finish turning of Inconel 718. Tool wear rate and wear mechanisms were evaluated for cutting speeds, 50<V<100 m/min, and feed rates, 0.075<f<0.125 mm/rev, at a constant depth of cut of 0.25 mm. It was concluded that abrasive and adhesive wear were the most dominant wear mechanisms, controlling the deterioration and final failure of the WC tools. While the triple layer CVD coated tools exhibited the highest wear resistance at high cutting speeds and low feeds, uncoated tools outperformed the single and multi-layer coated tools in the low range of cutting speeds and intermediate feeds. The cutting tool with single-layer PVD coating outperformed the other tools at the medium cutting speed. 相似文献
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10.
Zhang Yong Wang Qi Hou Ning Rao Shijie 《The International Journal of Advanced Manufacturing Technology》2020,106(11):4663-4673
The International Journal of Advanced Manufacturing Technology - This paper proposes a high-efficiency and high-precision processing method for Inconel 718 called electrochemical abrasive jet... 相似文献
11.
Domenico Umbrello 《The International Journal of Advanced Manufacturing Technology》2013,69(9-12):2183-2190
Machining of advanced aerospace materials have grown in the recent years although the diffucult-to-machine characteristics of alloys like titanium or nickel-based alloys cause higher cutting forces, rapid tool wear, and more heat generation. Therefore, machining with the use of cooling lubricants is usually carried out. To reduce the production costs and to make the processes environmentally safe, the goal is to move toward dry cutting by eliminating cutting fluids. This objective can be achieved by using coated tool, by increasing cutting speed, and by improving the product performance in term of surface integrity and product quality. The paper addresses the effects of cutting speed and feed on the surface integrity during dry machining of Inconel 718 alloy using coated tools. In particular, the influence of the cutting conditions on surface roughness, affected layer, microhardness, grain size, and microstructural alteration was investigated. Results show that cutting conditions have a significant effect on the parameters related to the surface integrity of the product affecting its overall performance. 相似文献
12.
Joon-Tae Yoo Jong-Hoon Yoon Ho-Sung Lee Sung-Kie Youn 《Journal of Mechanical Science and Technology》2014,28(8):3095-3102
Thickness profiled blank is designed via the optimization technique to maximize the bulged height in free bulging for Inconel 718. The thickness of the blank is described by the Bezier curve by using four control points. The location of each control points is used for the design variables of optimization. The material parameters for the flow stress equation of Inconel 718 are obtained from the free bulging test at constant pressure condition by using a flat blank and verified via numerical analysis. The objective function and constraints for optimization are the maximization of the bulged height within a limited strain range. The equivalent static load method for non-linear static response structural optimization with a move limit scheme is used for optimization. The result of optimization shows 21.95% increased bulged height and uniformly distributed strain after bulging. The free bulging test using blank with optimized profile is conducted to verify the optimization process. The results of bulged height and deformed shape are compared with those from numerical analysis, and the comparison shows good agreement. 相似文献
13.
Raju Shrihari Pawade Suhas S. Joshi 《The International Journal of Advanced Manufacturing Technology》2011,56(1-4):47-62
In this paper, a new effective approach, Taguchi grey relational analysis has been applied to experimental results in order to optimize the high-speed turning of Inconel 718 with consideration to multiple performance measures. The approach combines the orthogonal array design of experiments with grey relational analysis. Grey relational theory is adopted to determine the best process parameters that give lower magnitude of cutting forces as well as surface roughness. The response table and the grey relational grade graph for each level of the machining parameters have been established. The parameters: cutting speed, 475?m/min; feed rate, 0.10?mm/rev; depth of cut, 0.50?mm; and CW2 edge geometry have highest grey relational grade and therefore are the optimum parameter values producing better turning performance in terms of cutting forces and surface roughness. Depth of cut shows statistical significance on overall turning performance at 95% confidence interval. 相似文献
14.
为降低高沉积率激光金属沉积(Laser Metal Deposition,LMD)工艺中材料的孔隙率,研究了以镍基高温合金Inconel 718(IN718)为粉末沉积材料的高沉积率LMD工艺中主要工艺参数对材料孔隙率的影响,以及通过调整工艺参数降低材料孔隙率的方法。以目标沉积率为2kg/h的LMD工艺为基础,通过参数固化和分离的手段开展了高沉积率LMD的镀层实验,研究了主要工艺参数即激光功率、扫描速度及送粉量对LMD镀层材料孔隙率的影响,分析了不同参数下各镀层的横截面孔隙率及镀层孔隙率。实验显示:当激光功率从1 440 W增加到4 214 W时,镀层材料的孔隙率从约1.5%降低至0.02%左右;当扫描速度为500mm/min至5 000mm/min时,镀层材料孔隙率始终保持为0.07%至0.18%左右;当送粉量从0.64kg/h增加至6.48kg/h时,镀层材料孔隙率从约0.01%增加至0.84%左右。可见在高沉积率LMD工艺中,扫描速度对材料孔隙率无明显影响,而提高激光功率、限制送粉量均可有效降低LMD材料孔隙率,提高横截面孔隙率的一致性。 相似文献
15.
Abdullah M. Khalid Hafiz Evgueni V. Bordatchev Remus O. Tutunea-Fatan 《The International Journal of Advanced Manufacturing Technology》2014,70(9-12):1963-1978
An increasing number of recent technological advancement is linked to the widespread adoptions of ultra-short picosecond (ps) pulsed laser in various applications of material processing. The superior capability of this laser is associated with the precise control of laser–material interaction as an outcome of extremely short interaction times resulting in almost-negligible heat affected zones. In this context, the present study explores the applicability of a picosecond laser in laser micro-polishing (LμP) of Ni-based superalloy Inconel 718 (IN718). The specific research goals of the present study constitute determination of melting regime—a mandatory phase for LμP, establishing the concept of polishability of the spatial contents of the initial surface topography and experimental demonstration of the process capability of a ps laser for potential micro-polishing applications. The initial surface topography was prepared by micromilling operation with a step-over of 50 μm and scallop height of 2 μm. The LμP experiments were performed at five different levels of fluence associated with the melting regime by changing the focal offset, a parameter denoting the working distance between workpiece surface and focusing lens focal plane. The LμP performance was evaluated based on the line profiling average surface roughness (R a) spectrum distributed at different spatial wavelength intervals along the laser path trajectory. Furthermore, additional statistical metrics such as material ratio and power spectral density functions were analyzed in order to establish the process parameters associated with best achievable surface finish. The applicability of ps LμP was demonstrated in two regimes—1D (line) and 2D (area) polishing. During 1D LμP, significant (~52 %) improvement of the surface quality was achieved by reducing an R a value from 0.50 μm before polishing to an R a value of 0.24 μm across the laser path trajectory on initially ground surface. In addition, an initially micromilled area of 4.5?×?4.5 mm was LμPed resulting in the reduction of an areal topography surface roughness (S a) value from 0.435 to 0.127 μm (70.8 % surface quality improvement). 相似文献
16.
R. Thirumalai J. S. Senthilkumaar 《Journal of Mechanical Science and Technology》2013,27(4):1109-1116
Taguchi’s methods and design of experiments are invariably used and adopted as quality improvement techniques in several manufacturing industries as tools for offline quality control. These methods optimize single-response processes. However, Taguchi’s method is not appropriate for optimizing a multi-response problem. In other situations, multi-responses need to be optimized simultaneously. This paper presents multi-response optimization techniques. A set of non-dominated solutions are obtained using non-sorted genetic algorithm for multi-objective functions. Multi-criteria decision making (MCDM) is proposed in this work for selecting a single solution from nondominated solutions. This paper addresses a new method of MCDM concept based on technique for order preference by similarity to ideal solution (TOPSIS). TOPSIS determines the shortest distance to the positive-ideal solution and the greatest distance from the negative-ideal solution. This work involves the high-speed machining of Inconel 718 using carbide cutting tool with six objective functions that are considered as attributes against the process variables of cutting speed, feed, and depth of cut. The higher-ranked solution is selected as the best solution for the machining of Inconel 718 in its respective environment. 相似文献
17.
Juho Ratava Mika Lohtander 《The International Journal of Advanced Manufacturing Technology》2018,99(9-12):2081-2092
There are several methods of monitoring metal cutting processes. In this study, the combination of various methods in order to define an overall “cutting state” of a turning process is discussed along with an application to use these methods for adaptive fuzzy feed rate and cutting speed optimising control. For this purpose, different methods of monitoring individual cutting phenomena such as chip length and vibration level are aggregated and the combination of this information is considered to be the cutting state of the process. Expert data has been collected from a series of experiments concerning the apparent state of these phenomena as well as required control action. An adaptive optimizing fuzzy controller has been designed based on the concept of the cutting state and collected expert rules. The automatically classified cutting state as well as the control action based on this state is compared to expert data. There are notable differences which are analysed and solutions and further research are suggested based on the points requiring further improvement. 相似文献
18.
1 可加工性分析 Inconel 718材料属高硬度、高强度、耐腐蚀、耐高温镍基合金,主要用于制造飞机发动机涡轮盘、飞机机匣等高强度零件,此类零件在705℃以下具有耐高蠕变和抗应力断裂性能,在980℃以下具有良好的抗氧化性能(如涡轮转子、后机匣组件等). 相似文献
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20.
A. Madariaga J. A. Esnaola E. Fernandez P. J. Arrazola A. Garay F. Morel 《The International Journal of Advanced Manufacturing Technology》2014,71(9-12):1587-1598
Surface integrity (SI) and, particularly, the residual stress profile, has a great influence on the fatigue life of machined aeronautical critical parts. Among the different cutting parameters that affect the final SI, tool geometry is one of the most important factors. In particular, tool nose radius determines the surface roughness, as well as the thermoplastic deformation of the workpiece. Indeed, the use of large tool nose radius in the industry enables (1) increasing the feed rate while keeping the roughness values below specifications and (2) reducing the influence of the tool wear in the surface roughness. Therefore, in this study, the influence of tool nose radius in the induced residual stress profile and work-hardened layer when face turning Inconel 718 is analysed for a cutting speed range between (30–70 m/min) and a feed rate range of (0.15–0.25 mm/rev). For this purpose, residual stress profiles and work-hardened layer were measured by x-ray diffraction method after machining with a 4 mm nose radius. Then, results have been compared against different tool nose radius studies carried out by other authors for the specified working conditions. Results revealed that residual stress profiles varied when machining with different nose radius for the studied range. In particular, the increase of the nose radius brought to a higher difference between surface tensile stress and subsurface compressive peak stress, which is attributed to an increase of the thermal effect. Moreover, thicker work-hardened layer (around 100 μm) was observed when machining with large-nose radius for the studied working conditions. 相似文献