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Journal ArticleDOI

Improvement of Machinability using Laser-Aided Hybrid Machining for Inconel 718 Alloy

14 Jul 2016-Materials and Manufacturing Processes (Taylor & Francis)-Vol. 31, Iss: 14, pp 1825-1835
TL;DR: In this article, the influence of cutting conditions of Inconel 718 alloy during laser-assisted hybrid machining (LAHM) is investigated and the results are compared with conventional machining.
Abstract: Hybrid machining is an emerging technique for difficult-to-cut materials to overcome the problems associated with conventional machining (CM). Inconel 718, a super alloy of nickel, is a high-temperature alloy commonly used in aircraft and thermal industries and categorized as one among the difficult-to-cut materials. In this study, the influence of cutting conditions of Inconel 718 alloy during laser-assisted hybrid machining (LAHM) is investigated and the results are compared with CM. During LAHM, the process parameters of cutting speed, feed rate, approach angle, and laser power are varied. The present work is carried out in two phases: (i) determination of effective heat-affected depth (HAD) during laser preheating (using central composite design (CCD) in response surface methodology); (ii) optimization of cutting conditions during machining (using Taguchi's method). Compared with CM, the LAHM shows the following reduction benefits: (i) 33% in feed force (Fx), 42% in thrust force (Fy), and 28% in cutti...
Citations
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Journal ArticleDOI
K. Venkatesan1
TL;DR: In this article, the authors investigated the influence of input variables of laser assisted machining on the machinability aspect of the Inconel 718, a high-temperature alloy for high-performance aerospace gas turbine engines components.

65 citations


Cites background or result from "Improvement of Machinability using ..."

  • ...The results of the substrate and subsurface analysis showed that the surface finish on Inconel 718 is not been affected by heat during CM and LAT [23]....

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  • ...This result is in agreement with other research work [23]....

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Journal ArticleDOI
TL;DR: In this article, the authors compared the turning performance of Nimonic 90 using indigenously developed cryogenic-ultrasonic assisted turning (CUAT) process and CCA process and found that the results using CUAT process are better as compared to the CAT process in terms of decreased energy consumption (up to 20%), carbon emissions and overall machining cost.

43 citations

Journal ArticleDOI
TL;DR: Nickel alloys are extensively used in aerospace, automotive, marine, nuclear, petrochemical and food processing industries due to properties like high strength, resistance to heat and resistance to c...
Abstract: Nickel alloys are extensively used in aerospace, automotive, marine, nuclear, petro-chemical and food processing industries due to properties like high strength, resistance to heat, resistance to c...

39 citations


Cites background from "Improvement of Machinability using ..."

  • ...Venkatesan and Ramanujam (2016) studied the influence of cutting conditions in Laser Assisted Hybrid Machining (LAHM) for Inconel 718....

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Journal ArticleDOI
TL;DR: In this article, the machinability of Inconel 718 carbide inserts with low-cost laser assisted machining has been investigated using physical vapour disposition-coated (TiAlN)-carbide inserts in terms of cutting force, surface roughness, flank wear and chip formation.
Abstract: Laser-assisted machining (LAM) is a promising solution for all categories of difficult-to-machine materials like ceramics, metals and composites. Inconel 718, a difficult-to-machine material, is used in critical aero engine components. The objective of the study is to investigate its machining characteristics with low-cost cutting inserts using LAM. Therefore, in this paper, the machinability of this alloy has been investigated using physical vapour disposition-coated (TiAlN) carbide inserts in terms of cutting force, surface roughness, flank wear and chip formation in different range of cutting parameters. This investigation shows the improvement in machining performance of about 46, 36, 34, 50 44 and 68% for feed force, thrust force, cutting force, surface roughness and flank wear when compared to conventional machining (CM). For the criteria of benefit comparison, the detailed geometrical characteristic of produced chip and its morphology evaluation have been carried out under microscopic examination. The amplitude of this reduction is due to the maximum undeformed chip thickness of about 170 μm in LAM compared to CM.

33 citations

Journal ArticleDOI
TL;DR: In this article, a laser-assisted machining (LAM) was used to improve the machinability of fused silica by heating the workpiece locally in front of the cutting tool using a pulse CO2 laser beam.
Abstract: Fused silica is difficult to machine through conventional machining at room temperature, mainly due to high brittleness, low fracture toughness, high strength, and poor plastic deformation. In this study, we demonstrated experimentally that we are able to machine fused silica with improved efficiency and precision with laser-assisted machining (LAM) by heating workpiece locally in front of the cutting tool utilized a pulse CO2 laser beam. Then, the machinability of fused silica was evaluated. The surface roughness tests with a Taguchi orthogonal array indicated that the pulse duty ratio was the main factor for a minimum Ra value achievement. The experimental results demonstrated a considerable improvement in the machinability of fused silica through the improved surface quality, high material removal rate, low rate of tool wear, as well as the cutting force reduction. The material removal mechanism was a hybrid of quasi plastic deformation and brittle fracture during the LAM of fused silica, which was inferred from the machined surface quality and chip morphology changes compared to the conventional machining.

28 citations

References
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Journal ArticleDOI
TL;DR: In this article, the authors present an overview of major advances in machining techniques that have resulted to step increase in productivity, hence lower manufacturing cost, without adverse effect on the surface finish, surface integrity, circularity and hardness variation of the machined component.
Abstract: Significant advances have been made in understanding the behaviour of engineering materials when machining at higher cutting conditions from practical and theoretical standpoints. This approach has enabled the aerospace industry to cope with constant introduction of new materials that allow the engine temperature to increase at a rate of 10 °C per annum since the 1950s. Improvements achieved from research and development activities in this area have particularly enhanced the machining of difficult-to-cut nickel base and titanium alloys that have traditionally exhibited low machinability due to their peculiar characteristics such as poor thermal conductivity, high strength at elevated temperature, resistance to wear and chemical degradation, etc. A good understanding of the cutting tool materials, cutting conditions, processing time and functionality of the machined component will lead to efficient and economic machining of nickel and titanium base superalloys. This paper presents an overview of major advances in machining techniques that have resulted to step increase in productivity, hence lower manufacturing cost, without adverse effect on the surface finish, surface integrity, circularity and hardness variation of the machined component.

847 citations


"Improvement of Machinability using ..." refers background in this paper

  • ...Inconel 718 has broad operating temperature of up to 700 C which makes it attractive for aerospace applications [1]....

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Journal ArticleDOI
TL;DR: In this article, the authors focused on Inconel 718 and recent work and advances concerning machining of this material are presented, and some solutions to reduce the use of coolants are explored, and different coating techniques to enable a move towards dry machining are examined.
Abstract: The increasing attention to the environmental and health impacts of industry activities by governmental regulation and by the growing awareness in society is forcing manufacturers to reduce the use of lubricants. In the machining of aeronautical materials, classified as difficult-to-machine materials, the consumption of cooling lubricant during the machining operations is very important. The associated costs of coolant acquisition, use, disposal and washing the machined components are significant, up to four times the cost of consumable tooling used in the cutting operations. To reduce the costs of production and to make the processes environmentally safe, the goal of the aeronautical manufacturers is to move toward dry cutting by eliminating or minimising cutting fluids. This goal can be achieved by a clear understanding of the cutting fluid function in machining operations, in particular in high speed cutting, and by the development and the use of new materials for tools and coatings. High speed cutting is another important aspect of advanced manufacturing technology introduced to achieve high productivity and to save machining cost. The combination of high speed cutting and dry cutting for difficult-to-cut aerospace materials is the growing challenge to deal with the economic, environmental and health aspects of machining. In this paper, attention is focussed on Inconel 718 and recent work and advances concerning machining of this material are presented. In addition, some solutions to reduce the use of coolants are explored, and different coating techniques to enable a move towards dry machining are examined.

598 citations


"Improvement of Machinability using ..." refers background in this paper

  • ...In addition to this, the modified microstructure of subsurface, induced tensile residual stress, microcracks, and microhardness variations with white layer formation are the other problems [3]....

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Journal ArticleDOI
TL;DR: In this article, a general review of their material characteristics and properties together with their machinability assessment when using different cutting tools is presented, and the advantages and disadvantages of different tool materials with regard to the machining Inconel are highlighted.

536 citations


"Improvement of Machinability using ..." refers background in this paper

  • ...Hence, cutting of nickel-based super alloy using traditional machining is always associated with low cutting speed, poor surface finish, and subsurface damage, and thus machining costs are high [7, 8]....

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Journal ArticleDOI
15 Mar 2007-Wear
TL;DR: In this article, different carbide tools and different cutting conditions were tested in dry conditions, the elementary orthogonal cutting process was chosen, the cutting and feed cutting forces components were measured and the cutting force ratio calculated.

324 citations


"Improvement of Machinability using ..." refers background in this paper

  • ...This affects the built-up edge formation over cutting zone [2]....

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Journal ArticleDOI
TL;DR: In this article, an existing transient, three-dimensional heat transfer model is modified for modeling LAM of Inconel 718, and suitable coating conditions are determined for increasing the laser absorptivity in metals.
Abstract: Superalloys have high strengths at elevated temperatures, which make them attractive toward various applications and also make these materials difficult to machine at room temperature due to excessive tool wear and poor surface finish. Laser-assisted machining (LAM) offers the ability to machine superalloys more efficiently and economically by providing the local heating of the workpiece prior to material removal by a single point cutting tool. An existing transient, three-dimensional heat transfer model is modified for modeling LAM of Inconel 718. Suitable coating conditions are determined for increasing the laser absorptivity in metals and an approximate absorptivity value is determined. The thermal model is validated in axial and circumferential directions by temperature measurement using an infrared camera. The machinability of Inconel 718 under varying conditions is evaluated by examining tool wear, forces, surface roughness, and specific cutting energy. With increasing material removal temperature from room temperature to 620 °C, the benefit of LAM is demonstrated by a 25% decrease in specific cutting energy, a 2–3-fold improvement in surface roughness and a 200–300% increase in ceramic tool life over conventional machining. Moreover, an economic analysis shows significant benefits of LAM of Inconel 718 over conventional machining with carbide and ceramic inserts.

303 citations


"Improvement of Machinability using ..." refers methods in this paper

  • ...[19] investigated graphite-adhesive coating on workpiece surface to improve the absorptivity of metals like Inconel 718 while using CO2 laser source....

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