Abstract
In the current scenario, machinability of the super alloys is of greater importance in an aircraft turbine engine and land-based turbine applications owing to its superior properties. However, the machinability of these alloys is found to be poor owing to its inherent properties. Hence, a predictive model has been developed based on DEFORM 3D to forecast the machining attributes such as cutting force and insert's cutting edge temperature in turning of Nimonic C263 super alloy. The dry turning trials on Nimonic C263 material were carried out based on L27 orthogonal array using CBN insert. Linear regression models were developed to predict the machining attributes. Further, multi response optimization was carried out based on desirability approach for optimizing the machining attributes. The validation test was carried out for optimal parameter values such as cutting speed: 117 m/min, feed rate: 0.055 mm/rev and depth of cut: 0.25 mm. The minimum cutting force of 304N and insert's cutting edge temperature of 468 °C were obtained at optimum level of parameters.The predicted values by FEA and linear regression model were compared with experimental results and found to be closer with minimum percentage error.The minimum percentage error obtained by FEA and linear regression model for the machining attributes (cutting force, temperature) as compared with experimental values were (0.32%, 0.23%) and (2.34%, 1.63%) respectively.
Highlights
High strength alloy Nimonic C263 has been widely used in many crucial parts of aircraftin high-temperature environments owing to its excellent mechanical properties, fatigue strength and creep properties
Uma et al [5] stated that the analyses of the impact of the controlling factors experimentally in the machining processes are tough and costly, the DEFORM 3D was used as a tool to simulate the machining attributes in turning of Inconel 718
Was not carried out adequately earlier by previous researchers.the present study investigates the impact of factors on cutting force, the temperature at insert edge, in turning Nimonic C263 to get improved machinability
Summary
High strength alloy Nimonic C263 has been widely used in many crucial parts of aircraftin high-temperature environments owing to its excellent mechanical properties, fatigue strength and creep properties. Pradhana et al [3] conducted turning experiments on titanium alloy and the experimentally observed results were compared with the predicted values by DEFORM 3D They have considered the tool and workpiece as rigid and plastic respectively. Uma et al [5] stated that the analyses of the impact of the controlling factors experimentally in the machining processes are tough and costly, the DEFORM 3D was used as a tool to simulate the machining attributes in turning of Inconel 718. The study on its machinability at high speed with CBN was not carried out adequately earlier by previous researchers.the present study investigates the impact of factors on cutting force, the temperature at insert edge, in turning Nimonic C263 to get improved machinability
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