Optimization and Finite Element Modelling of Tool Wear in Milling of Inconel 625 Superalloy

Year 2021, Volume: 24 Issue: 2, 391 - 400, 01.06.2021

Mahir Akgün , Halil Demir

https://doi.org/10.2339/politeknik.706605

Cited By: 10

Abstract

This study focuses on optimization of cutting conditions and numerical analysis of flank wear in milling of Inconel 625 superalloy using PVD AlTiN and CVD TiCN/Al2O3/TiN-coated carbide inserts. The milling experiments have been performed in CNC vertical machining centre according to Taguchi L18 orthogonal array. Finite element modelling of tool wear was performed using Deform 3D software. Analysis of variance was utilized to define the influences of the milling conditions on Vb. The results showed that the feed rate (with 41.5% contribution rate) is the most important parameter affecting Vb. The linear and quadratic regression analyses were used to estimate the results of the test. The regression analysis results showed that the estimated Vb values achieved by the quadratic regression model were more effective compared to the linear regression model. Statistical results revealed that the Taguchi method was successful to define optimum cutting parameters in the milling of Inconel 625.

Keywords

Inconel 625, Milling, Tool Wear, Finite Element Method, taguchi

Supporting Institution

TÜBİTAK

Project Number

119M785

Thanks

The authors would like to thank the Scientific and Technological Research Council of Turkey (TÜBİTAK) for the financial support with project number 119M785.

References

• [1].https://www.kennametal.com/content/dam/kennametal/kennametal/common/Resources/CatalogsLiterature/Metalworking/SuperAlloys_material_machining_guide_Aerospace.pdf.” . Accessed 17 Dec 2019.
• [2]. Wang Z., Guan K., Gao M., “The microstructure and mechanical properties of deposited-IN718 by selective laser melting”, Journal of Alloys and Compounds 513:518–523, (2012).
• [3]. Jindal P., Santhanam A., Schleinkofer U., Shuster A., “Performance of PVD TiN, TiCN, and TiAlN coated cemented carbide tools in turning”, International Journal of Refractory Metals and Hard Materials, 17: 163–170, (1999).
• [4]. Sokovic M., Kopac J., Dobrzanski L. A., Mikula J., Golombek K., Pakula D., “Cutting Characteristics of PVD and CVD - Coated Ceramic Tool Inserts”, Tribology in Industry, 28:3–8, (2006).
• [5]. Kıvak T., “Optimization of surface roughness and flank wear using the Taguchi method in milling of Hadfield steel with PVD and CVD coated inserts”, Measurement, 50: 19–28, (2014).
• [6]. Horng J. T., Liu N. M., Chiang K. T., “Investigating the machinability evaluation of Hadfield steel in the hard turning with Al2O3/TiC mixed ceramic tool based on the response surface methodology”, Journal of Materials Processing Technology, 208: 532–541, (2008).
• [7]. Chethan Y. D., Ravindra H. V., Krishnegowda Y. T., “Optimization of machining parameters in turning Nimonic-75 using machine vision and acoustic emission signals by Taguchi technique”, Measurement, 144: 144–154, (2019).
• [8]. Akgün M., Demir H., Çiftçi İ., “Optimization of Surface Roughness in Turning Mg2Si Particle Reinforced Magnesium”, Journal of Polytechnic, 21(3): 645-650, (2018).
• [9]. Yan H., Hua J., Shivpuri R., “Flow stress of AISI H13 die steel in hard machining”, Materials & Design 28: 272–277, (2007).
• [10]. Kalyon A., Günay M., Özyürek D., “Application of grey relational analysis based on Taguchi method for optimizing machining parameters in hard turning of high chrome cast iron”, Advances in Manufacturing, 6: 419–429, (2018).
• [11]. Yaşar N., “Thrust force modelling and surface roughness optimization in drilling of AA-7075: FEM and GRA”, Journal of Mechanical Science and Technology, 33: 4771–4781, (2019).
• [12]. Korkmaz M. E., Günay M., “Finite Element Modelling of Cutting Forces and Power Consumption in Turning of AISI 420 Martensitic Stainless Steel”, Arabian Journal for Science and Engineering, 43: 4863–4870, (2018).
• [13]. Özel T., The influence of friction models on finite element simulations of machining. International Journal of Machine Tools and Manufacture, 46: 518–530, (2006).
• [14]. Johnson G. J., Cook W.,“A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures”, In Proceedings of the Seventh International Symposium on Ballistics, The Hague, pp; 541–547, (1983).
• [15]. Dorogoy A., Rittel D., “Determination of the Johnson–Cook Material Parameters Using the SCS Specimen”, Experimental Mechanics, 49: 881, (2008).
• [16]. Takeyama H. M. R., “Basic investigation of tool wear”, ASME J Eng Ind 85:c38, (1963).
• [17]. Usui E., Shirakashi T. K. T., “Analytical prediction of three dimensional cutting process, part 3: cutting temperature and crater wear of carbide too”. ASME J Eng Ind, 100: 236–243, (1978).
• [18]. Wong T., Kim W., Kwon P., “Experimental support for a model-based prediction of tool wear”, Wear, 257: 790–798, (2004).
• [19]. Trigger K. J., Chao B. T., “The mechanism of crater wear of cemented carbide tools”, Trans ASME,78:1119, (1956).
• [20]. Lotfi M., Jahanbakhsh M., Akhavan F. A., “Wear estimation of ceramic and coated carbide tools in turning of Inconel 625: 3D FE analysis”, Tribology International, 99: 107–116, (2016).
• [21]. https://www.specialmetals.com/assets/smc/documents/alloys/inconel/inconel-alloy-625.pdf. Accessed 17 Dec 2019.
• [22]. Cetin M. H., Ozcelik B., Kuram E., Demirbas E., “Evaluation of vegetable based cutting fluids with extreme pressure and cutting parameters in turning of AISI 304L by Taguchi method”, Journal of Cleaner Production, 19: 2049–2056, (2011).
• [23]. Kara F., Öztürk B., “Comparison and optimization of PVD and CVD method on surface roughness and flank wear in hard-machining of DIN 1.2738 mold steel”. Sensor Review, 39: 24–33, (2019).