Abstract
The objective of this research was to investigate the effectiveness of application of liquid nitrogen (LN2) in turning of Inconel 718 compared to flooded cutting and select suitable LN2 cutting parameters using response surface methodology (RSM). The results of turning experiments conducted by spraying LN2 to the cutting area of Inconel 718 bar showed that using either low or high cutting parameters, cutting performance of Inconel 718 under the cryogenic condition was generally worse than the flooded cutting. However, using the medium cutting parameters, the LN2 cutting performance was as good as that of the flooded cutting both showing a cutting force of 90 N, 60 µm of flank wear and 0.5–0.6 µm of surface roughness (Ra). These parameters were further optimized using desirability function of RSM to determine the set of parameters that provided the lowest cutting force, flank wear and Ra values and the highest material removal rate (MRR) under cryogenic cutting. Analysis of variance (ANOVA) performed on the regression models developed showed that cutting speed was the only significant factor on the cutting force. Feed rate was the most influential parameter on the flank wear. Feed rate and depth of cut were significant factors both affecting Ra. Multi-objective optimization showed that a cutting speed of 87 m/min, a feed rate of 0.06 mm/rev and a depth of cut of 0.37 mm constituted the optimum cutting parameters for achieving a cutting force of 78 N, flank wear of 58 µm, Ra of 0.49 µm and the MRR of 1.97 cm3/min under the cryogenic cutting condition.
Highlights
Inconel 718 is a widely used nickel-based superalloy with high corrosion and creep resistance for elevated temperature applications
The objective of this section is to determine any difference in variation of cutting force, flank wear and surface roughness with cutting speed and feed rate when LN2 is applied to the cutting edge in comparison to conventional flooded cutting
Effect of cryogenic turning on Inconel 718 was experimentally investigated by determining the flank wear, cutting force and Ra surface roughness at different cutting speeds and feed rates and comparing them with those obtained from flooded and dry conditions
Summary
Inconel 718 is a widely used nickel-based superalloy with high corrosion and creep resistance for elevated temperature applications. Various methods have been proposed to facilitate cutting process during machining of nickel-based superalloys including high-pressure machining [7], utilization of nano-fluids [8], laser-assisted machining [9], heat-assisted machining [10, 11] and hybrid machining (application of two or more of the mentioned cutting conditions at the same time) [12]. Another effective method is application of a cryogen (liquefied gas such as liquid nitrogen or CO2) during the cutting process. The literature survey presented in the following parts of this section summarizes the previous experimental works on cryogenic machining of nickelbased superalloys and reviews the related statistical analyses methods for the optimization of machining parameters
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