Manufacturing Technology Today

Dinesh Thakur ¹, B. Ramamoorthy ¹, L. Vijayaraghavan ¹

Affiliations
1 Manufacturing Engineering Section, Mechanical Engg. Department, IIT Madras, Chennai, IN

Abstract

Superalloy, Inconel 718 is from the category of "Difficult to Cut" materials. The applications of Inconel 718 is not only limited to aerospace, gas turbine, marine, space applications but also to the chemical process industry, automotive sector etc. due to its unique properties which are desirable in the engineering applications. However, due to its peculiar characteristics, machining of Inconel 718 has poor machinability. The present work is a preliminary experimental study based on the Merchant metal cutting theory for Inconel 718. The experiments were carried out on Inconel 718 workpiece using plain tungsten carbide (K20) insert tools. The objective of this study is to evaluate machinability factors such as cutting force, chip compression ratio or chip reduction coefficient (ζ), shear angle (Φ) and specific cutting pressure using Taguchi's optimization approach. Also chip analysis was carried out by varying the cutting parameters. The mathematical model and the results are presented and analyzed in this paper.

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R. Vikram Kumar ¹, A. S. Varadharajan ¹, B. Ramamoorthy ¹

Affiliations
1 Department of Mechanical Engineering, Indian Institute Technology, Madras, Chennai-600 036, IN

Abstract

The concept of hard turning has gained considerabie attention in the recent past in metai cutting as it can apparentiy replace the traditional process cycle which comprises rough turning, heat treatment and finish grinding. The fine finishing processes decisively influence the functional behavior of machined part. In hard turning the fine finishing is performed by turning and the result is similar to that of grinding. Surface finish obtained in hard turning is one of the important factors, which plays a major role in the functional behavior of any component. Generally in hard turning copious amount of cutting fluid is used. Hard turning with Minimum fluid application (HTMF) is a new strategy, in which extremely small quantity of specially prepared cutting fluid is applied precisely at the cutting zone. The present work deals with the comparison of surface finish obtained in HTMF with conventional wet and dry turning. The influence of the machining and minimum fluid application parameters on the surface roughness has been studied using statistical design of experiments and analyzed in this work.

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