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A Numerical Study on Heat-Assisted Machining of Monel K-500 Alloy

Year 2022, Volume: 14 Issue: 1, 23 - 29, 30.04.2022
https://doi.org/10.55974/utbd.1063676

Abstract

This study presents the investigation of the cutting force and chip formation process in hot machining of Monel K-500 alloy via finite element analysis. ThirdWave AdvantEdge software has been utilized for finite element analysis. For numerical analysis, cutting speed of 300 m/min, feed rate of 0.1 mm/rev, and 1 mm depth of cut have been selected as cutting parameters. Cutting simulations have been performed at room temperature (24°C) and four different heating temperatures (150°C, 300°C, 450°C, and 600°C) to determine the effect of hot processing. According to the results of the numerical analysis, it was observed that the cutting forces decreased in hot machining conditions compared to room temperature conditions, and the chip formed in the form of segmented chips in room temperature conditions, while it was formed as continuous type chips in hot machining conditions. The lowest cutting force value was measured as 315 N in numerical analyzes performed at 300 m/min cutting speed, 0.1 mm/rev feed rate, 1 mm depth of cut, and 600°C hot machining conditions. Moreover, it was determined that the cutting force decreased by approximately 34.14% at this heating temperature compared to the dry cutting condition.

References

  • Nurul Amin AKM, Ginta TL. Heat-Assisted Machining. Comprehensive Materials Processing, 11, 297–331, 2014.
  • Özler L, Inan Theoretical A, Özel C. and experimental determination of tool life in hot machining of austenitic manganese steel. International Journal of Machine Tools and Manufacture, 41(2), 163–172, 2001.
  • Sun S, Brandt M, Dargusch MS. Thermally enhanced machining of hard-to-machine materials—A review. International Journal of Machine Tools and Manufacture, 50(8), 663–680, 2010.
  • Novak JW, Shin YC, Incropera FP. Assessment of Plasma Enhanced Machining for Improved Machinability of Inconel 718. Journal of Manufacturing Science and Engineering, 119(1), 125–129, 1997.
  • Kizaki T, Harada K, Mitsuishi M. Efficient and precise cutting of zirconia ceramics using heated cutting tool. CIRP Ann., 63(1), 105–108, 2014.
  • Sofuoğlu MA, Çakır FH, Gürgen S, Orak S, Kuşhan MC. Experimental investigation of machining characteristics and chatter stability for Hastelloy-X with ultrasonic and hot turning. The International Journal of Advanced Manufacturing Technology, 95(1), 83–97, 2018.
  • Parida AK, Maity K. FEM analysis and experimental investigation of force and chip formation on hot turning of Inconel 625. Defence Technology, 15(6), 853-860, 2019.
  • Luan X, Meng J, Huang B, Dong X, Hu Y, Zhao Y, Qu L. Machining characteristics of Ti6Al4V alloy in laser-assisted machining under minimum quantity lubricant. The International Journal of Advanced Manufacturing Technology, 112(3), 775-785, 2021.
  • Jeong HI, Lee CM. A study on improvement of tool life using a heat shield in laser assisted machining to Inconel 718. Optics & Laser Technology, 142, 107208, 2021.
  • Mitrofanov AV, Babitsky VA, Silberschmidt VV. Finite element simulations of ultrasonically assisted turning. Computational materials science, 28(3-4), 645-653, 2003.
  • Cakir FH, Gurgen S, Sofuoglu MA, Celik ON, Kushan MC. Finite element modeling of ultrasonic assisted turning of Ti6Al4V alloy. Procedia-Social and Behavioral Sciences, 195, 2839-2848, 2015.
  • Pandey K, Datta S. Hot machining of difficult-to-cut materials: A review. Materials Today: Proceedings, 44, 2710-2715, 2021.
  • Xu W, Liu X, Sun J, Zhang L. Finite element simulation and experimental research on electric hot machining. The International Journal of Advanced Manufacturing Technology, 66(1-4), 407-415, 2013.
  • Parida AK, Maity K. Numerical analysis of chip geometry on hot machining of nickel base alloy. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40(10), 1-9, 2018.
  • Rotella G, Umbrello D. Numerical simulation of surface modification in dry and cryogenic machining of AA7075 alloy. Procedia Cirp, 13, 327-332, 2014.
  • Amini S, Soleimanimehr H, Nategh MJ, Abudollah A, Sadeghi MH. FEM analysis of ultrasonic-vibration-assisted turning and the vibratory tool. Journal of materials processing technology, 201(1-3), 43-47, 2008.
  • Parida AK, Maity K. Analysis of some critical aspects in hot machining of Ti-5553 superalloy: experimental and FE analysis. Defence Technology, 15(3), 344-352, 2019.
  • Kaynak Y, Gharibi A, Ozkutuk M. Experimental and numerical study of chip formation in orthogonal cutting of Ti-5553 alloy: the influence of cryogenic, MQL, and high pressure coolant supply. The International Journal of Advanced Manufacturing Technology, 94(1), 1411-1428, 2018.
  • Yalcin B, Yilmaz N, Kurt A. Tool Stresses in Soft and Hard Finish Turning with Low Content CBN Tool by Finite Elements Analysis. Acta Physica Polonica, A., 134(1), 48-56, 2018.
  • Özlü B, Uğur L. Optimization of cutting forces on turning of Ti-6Al-4V Alloy by 3D FEM simulation analysis. Journal of Engineering Research and Applied Science, 10(2), 1789-1795, 2021.
  • Trent EM, Metal Cutting, Butterworths Pres, London, 1989.
  • Akkuş H, Yaka H. Experimental and statistical investigation of the effect of cutting parameters on surface roughness, vibration and energy consumption in machining of titanium 6Al-4V ELI (grade 5) alloy. Measurement, 167, 108465, 2021.
  • Parida AK, Maity K. Comparison the machinability of Inconel 718, Inconel 625 and Monel 400 in hot turning operation. Engineering Science and Technology, an International Journal, 21(3), 364-370, 2018.
  • Lajis MA, Amin AKM, Karim AN. Surface integrity in hot machining of AISI D2 hardened steel. In Advanced Materials Research. 500, 44-50, 2012.
  • Korkmaz ME, Günay M. Finite Element Modelling of Cutting Forces and Power Consumption in Turning of AISI 420 Martensitic Stainless Steel. Arabian Journal for Science & Engineering, 43(9), 4863–4870, 2018.
  • Thandra SK, Choudhury SK. Effect of cutting parameters on cutting force, surface finish and tool wear in hot machining. International Journal of Machining and Machinability of Materials, 7(3-4), 260-273, 2010.
  • Parida AK, Maity K. Effect of nose radius on forces, and process parameters in hot machining of Inconel 718 using finite element analysis. Engineering Science and Technology, an International Journal, 20(2), 687-693, 2017.

Monel K-500 Alaşımının Isı Destekli İşlenmesi Üzerine Sayısal Bir Çalışma

Year 2022, Volume: 14 Issue: 1, 23 - 29, 30.04.2022
https://doi.org/10.55974/utbd.1063676

Abstract

Bu çalışma, sonlu elemanlar analizi aracılığı ile Monel K-500 alaşımının sıcak işlenmesinde kesme kuvveti ve talaş oluşum sürecinin incelenmesini sunmaktadır. Sonlu elemanlar analizi için ThirdWave AdvantEdge yazılımı kullanılmıştır. Sayısal analizler için 300 m/dak kesme hızı (Vc), 0,1 mm/dev ilerleme miktarı (f) ve 1 mm talaş derinliği (a) kesme parametreleri olarak seçilmiştir. Sıcak işlemenin etkisini belirleyebilmek için simülasyonlar oda sıcaklığı (24°C) ve dört farklı ısıtma sıcaklığında (150°C, 300°C, 450°C ve 600°C) gerçekleştirilmiştir. Nümerik analiz sonuçlarına göre oda sıcaklığı koşullarına kıyasla sıcak işleme koşullarında kesme kuvvetlerinin azaldığı ve oda sıcaklığı koşullarında talaş dilimli talaş şeklinde oluşur iken sıcak işleme koşullarında ise sürekli talaş şeklinde oluştuğu görülmüştür. En düşük kesme kuvveti değeri 600°C sıcak işleme şartında gerçekleştirilen sayısal analizlerde 315 N olarak ölçülmüştür. Dahası, kuru kesme şartına göre bu ısıtma sıcaklığında kesme kuvvetinin yaklaşık %34,14 azaldığı tespit edilmiştir.

References

  • Nurul Amin AKM, Ginta TL. Heat-Assisted Machining. Comprehensive Materials Processing, 11, 297–331, 2014.
  • Özler L, Inan Theoretical A, Özel C. and experimental determination of tool life in hot machining of austenitic manganese steel. International Journal of Machine Tools and Manufacture, 41(2), 163–172, 2001.
  • Sun S, Brandt M, Dargusch MS. Thermally enhanced machining of hard-to-machine materials—A review. International Journal of Machine Tools and Manufacture, 50(8), 663–680, 2010.
  • Novak JW, Shin YC, Incropera FP. Assessment of Plasma Enhanced Machining for Improved Machinability of Inconel 718. Journal of Manufacturing Science and Engineering, 119(1), 125–129, 1997.
  • Kizaki T, Harada K, Mitsuishi M. Efficient and precise cutting of zirconia ceramics using heated cutting tool. CIRP Ann., 63(1), 105–108, 2014.
  • Sofuoğlu MA, Çakır FH, Gürgen S, Orak S, Kuşhan MC. Experimental investigation of machining characteristics and chatter stability for Hastelloy-X with ultrasonic and hot turning. The International Journal of Advanced Manufacturing Technology, 95(1), 83–97, 2018.
  • Parida AK, Maity K. FEM analysis and experimental investigation of force and chip formation on hot turning of Inconel 625. Defence Technology, 15(6), 853-860, 2019.
  • Luan X, Meng J, Huang B, Dong X, Hu Y, Zhao Y, Qu L. Machining characteristics of Ti6Al4V alloy in laser-assisted machining under minimum quantity lubricant. The International Journal of Advanced Manufacturing Technology, 112(3), 775-785, 2021.
  • Jeong HI, Lee CM. A study on improvement of tool life using a heat shield in laser assisted machining to Inconel 718. Optics & Laser Technology, 142, 107208, 2021.
  • Mitrofanov AV, Babitsky VA, Silberschmidt VV. Finite element simulations of ultrasonically assisted turning. Computational materials science, 28(3-4), 645-653, 2003.
  • Cakir FH, Gurgen S, Sofuoglu MA, Celik ON, Kushan MC. Finite element modeling of ultrasonic assisted turning of Ti6Al4V alloy. Procedia-Social and Behavioral Sciences, 195, 2839-2848, 2015.
  • Pandey K, Datta S. Hot machining of difficult-to-cut materials: A review. Materials Today: Proceedings, 44, 2710-2715, 2021.
  • Xu W, Liu X, Sun J, Zhang L. Finite element simulation and experimental research on electric hot machining. The International Journal of Advanced Manufacturing Technology, 66(1-4), 407-415, 2013.
  • Parida AK, Maity K. Numerical analysis of chip geometry on hot machining of nickel base alloy. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40(10), 1-9, 2018.
  • Rotella G, Umbrello D. Numerical simulation of surface modification in dry and cryogenic machining of AA7075 alloy. Procedia Cirp, 13, 327-332, 2014.
  • Amini S, Soleimanimehr H, Nategh MJ, Abudollah A, Sadeghi MH. FEM analysis of ultrasonic-vibration-assisted turning and the vibratory tool. Journal of materials processing technology, 201(1-3), 43-47, 2008.
  • Parida AK, Maity K. Analysis of some critical aspects in hot machining of Ti-5553 superalloy: experimental and FE analysis. Defence Technology, 15(3), 344-352, 2019.
  • Kaynak Y, Gharibi A, Ozkutuk M. Experimental and numerical study of chip formation in orthogonal cutting of Ti-5553 alloy: the influence of cryogenic, MQL, and high pressure coolant supply. The International Journal of Advanced Manufacturing Technology, 94(1), 1411-1428, 2018.
  • Yalcin B, Yilmaz N, Kurt A. Tool Stresses in Soft and Hard Finish Turning with Low Content CBN Tool by Finite Elements Analysis. Acta Physica Polonica, A., 134(1), 48-56, 2018.
  • Özlü B, Uğur L. Optimization of cutting forces on turning of Ti-6Al-4V Alloy by 3D FEM simulation analysis. Journal of Engineering Research and Applied Science, 10(2), 1789-1795, 2021.
  • Trent EM, Metal Cutting, Butterworths Pres, London, 1989.
  • Akkuş H, Yaka H. Experimental and statistical investigation of the effect of cutting parameters on surface roughness, vibration and energy consumption in machining of titanium 6Al-4V ELI (grade 5) alloy. Measurement, 167, 108465, 2021.
  • Parida AK, Maity K. Comparison the machinability of Inconel 718, Inconel 625 and Monel 400 in hot turning operation. Engineering Science and Technology, an International Journal, 21(3), 364-370, 2018.
  • Lajis MA, Amin AKM, Karim AN. Surface integrity in hot machining of AISI D2 hardened steel. In Advanced Materials Research. 500, 44-50, 2012.
  • Korkmaz ME, Günay M. Finite Element Modelling of Cutting Forces and Power Consumption in Turning of AISI 420 Martensitic Stainless Steel. Arabian Journal for Science & Engineering, 43(9), 4863–4870, 2018.
  • Thandra SK, Choudhury SK. Effect of cutting parameters on cutting force, surface finish and tool wear in hot machining. International Journal of Machining and Machinability of Materials, 7(3-4), 260-273, 2010.
  • Parida AK, Maity K. Effect of nose radius on forces, and process parameters in hot machining of Inconel 718 using finite element analysis. Engineering Science and Technology, an International Journal, 20(2), 687-693, 2017.
There are 27 citations in total.

Details

Primary Language Turkish
Subjects Mechanical Engineering
Journal Section Articles
Authors

Mahir Akgün 0000-0002-4522-066X

Publication Date April 30, 2022
Published in Issue Year 2022 Volume: 14 Issue: 1

Cite

IEEE M. Akgün, “Monel K-500 Alaşımının Isı Destekli İşlenmesi Üzerine Sayısal Bir Çalışma”, IJTS, vol. 14, no. 1, pp. 23–29, 2022, doi: 10.55974/utbd.1063676.

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