Abstract
The high hardness and low thermal diffusivity along with the tremendous strength at high temperatures has rendered the nickel-base super alloys Inconel 718 one of the most difficult to cut material. It possesses a wide range of applications including aerospace as well as chemical and petrochemical industries, and is primarily used in the manufacture of aircraft gas turbines, space vehicles, nuclear power systems, and medical equipment. The present study is mainly focused on the cutting parameters optimization that leads to minimum surface roughness, cutting force and power, specific energy and maximum productivity during the turning of the molded Inconel 718 using a carbide cutting tool. The analysis of variance (ANOVA) method is applied to identify the cutting parameters that most influence the response criteria, and the response surface methodology (RSM) along with the desirability function (DF) approaches are further used to develop the prediction model that addresses the optimization procedure. The different parameters are considered one at a time in order to evaluate the sensitivity of the response (OFAT). This procedure led to identify the nose radius (rε), the feed rate (f), the depth of cut (ap) and the cutting speed (Vc) as the most significant factors on both the surface roughness and the cutting forces. Furthermore, the product (f × ap) and the cutting speed (Vc) were found to be the most dominant factors on the specific energy.
Highlights
Nickel base alloys such as Inconel 718 (NC19FeNb according to European standards) are the heat resistant super alloys that are widely used in the manufacture of aero-engine, rocket and submarine components that run at temperatures comprised between 450 °C and 700 °C [1,2]
Design of experiments is a standard tool used to conduct the experiment in an optimum way to investigate the effects of process parameters illustrated by the cutting conditions and represented by the feed rate (f), the nose radius and the cutting speed (Vc) on the response or output parameters i.e. the surface roughness and the three components of the cutting force (Fa, Fr and Ft) during the machining of the Ni-based super alloy Inconel 718
According to above-mentioned results pertaining to the parametric tests, it is possible to conclude that machining Inconel 718 under high cutting speed values, high feed rate and low nose radius presents the optimum combination case that leads to simultaneously improve the surface quality along with cutting forces
Summary
Nickel base alloys such as Inconel 718 (NC19FeNb according to European standards) are the heat resistant super alloys that are widely used in the manufacture of aero-engine, rocket and submarine components that run at temperatures comprised between 450 °C and 700 °C [1,2]. The characteristics that lead to it being one of the most important engineering materials are likewise responsible for its poor machinability that usually results in limited tool life and poor surface quality and high costs [3,4,5]. These are the main reasons that led numerous investigators to carrying out various studies aiming to optimize the machinability of this type of material. The work carried out in this research involves the investigation and optimization of the cutting conditions pertaining to the molded Inconel 718 in order to achieve better surface quality, cutting force and productivity
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