Raju Pawade

Chip segmentation behaviour and surface topography in high-speed turning of titanium alloy (Ti-6Al-4V) with eco-friendly water vapour

In this paper, a new eco-friendly approach of use of water vapour cooling is presented to machine titanium alloy (Ti-6Al-4V) at higher cutting speed. A plain turning operation was carried out for three different cutting speeds (60, 120, 180 m/min) and feedrates (0.08, 0.16, 0.32 mm/rev) with constant depth of cut. The machining performance is evaluated in terms of chip thickness ratio, chip segmentation frequency, surface roughness and surface damage. The experimental study revealed that at higher cutting speed the chips become more ductile and show continuous morphology with serrated tooth because of increased temperature of shear zone and concentrated shear in the deformation zone. It is observed that chip thickness ratio and cross sectional area of the chip is increased with an increase in feedrate for all cutting speeds. The surface finish was improved when snarled and ribbon type chips are formed. Pitch of the chip is decreased as the cutting speed increases for all the feedrates. A significant change in surface roughness was found at different feedrates as compared to cutting speed. A variety of surface alterations are found which vary according to machining conditions.

Surface quality analysis in ball end milling of Inconel 718 cantilevers by response surface methodology

The ball end milling process is commonly used for generating complex three-dimensional sculptured surfaces with definite curvature. In such cases, variation of surface properties along with the machined surface is not well understood. Therefore, this article investigates the effect of machining parameters on the quality of surface in ball end milling of thin-shaped cantilever of Inconel 718. A distinct variation is also observed in the measured values of deflection of workpiece: surface roughness and surface damage in different regions, that is, fixed end, mid portion and free end of machined surface. The experiments were conducted according to the central composite design with four factors, namely, cutting speed, feed, workpiece thickness and workpiece inclination with tool path orientation. It is observed that the process parameters have statistically significant effect on machined surface of Inconel 718. Horizontal tool path condition during milling is most favourable in all aspects of surface quality with high speed and lower feed. The surface roughness values at the fixed end of plate are less as compared with that of mid portion and free end sides. Scanning electron microscope images show various defects such as side flow, smeared layer, microparticle, grooves and feed marks.

Application of Teaching: Learning Based optimization to Surface Integrity Parameters in Milling

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Multi Objective Optimization Using Taguchi Grey Relational Analysis (Gra) for Cnc Turning of Poly-Ether-Ether-Ketone (Peek) Polymer

The paper attempts to implement the multi objective optimization methodology for poly-ether-ether-ketone (PEEK) polymer by using CNC turning machine. For the same, Taguchi based L18 experiments were carried out on CNC turning lathe using TiC and TiN coated carbide inserts. Further, the process performance is measured in terms of cutting forces and surface roughness. The optimized machining parameters were determined using Grey Relational Analysis (GRA). The analysis of results shows that cutting speed: 377 m/min, feed rate: 0.05 mm/rev, depth of cut: 2 mm and TiC insert exhibits better results.

Sustainability modelling and assessment in high-speed turning of Inconel 718

The severe urge for need of cleaner machining techniques has led to continuous exploration of various alternative cooling and lubrication methods. Surface integrity of machined components play a crucial role, but the same cannot be the only criteria for deciding on the machinability aspects as well as eco-friendliness of specific machining approach. This paper proposes a model for sustainability assessment of machining considering surface integrity aspects along with machining environment aspects for better understanding of sustainability in machining. High-speed turning of Inconel 718 at varying MRR levels depicting productivity rates has been carried out under dry, flood coolant and water vapour machining environments, and then sustainability assessment has been carried out using the developed model. Within the investigated experimental regime, the results show that the use of water vapour as coolant and lubricant in machining gives highest product sustainability index (PSI) of 82.92% thus suggesting it to be a promising eco-friendly machining technique.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

Abstract This paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

Surface Integrity Studies in Ball End Milling of Thin Shaped Cantilever Inconel 718

The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever plate of Inconel 718. It is noticed that the workpiece deflection has significantly contributed to machined surface integrity in terms of surface topography and subsurface microhardness. The ball end milling performed with 15° workpiece inclination with horizontal tool path produced higher surface integrity which varies with the location of machined surface region. In general, the mid portion of the machined plate shows lower surface roughness and microhardness with less surface defects.Copyright