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Experimental Study on Tool Wear and Cutting Temperature during Machining of Nimonic C-263 and Waspaloy Based on Taguchi Method and Response Surface Methodology

Sri Sairam Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan, Devendiran Sundararajan
  • Technical Paper
  • 2019-28-0144
To be published on 2019-10-11 by SAE International in United States
Nickel based materials of Nimonic C-263 and Waspaloy are used nowadays for aerospace applications owing to its superior strength properties that are maintained at a higher temperature. Tool wear and cutting temperature in the vicinity of cutting edge are two essential machinability characteristics for any cutting tool. In this regard, this study is pursued to examine the influence of factors on measuring of tool wear (Vba) and cutting temperature (Ts) during dry machining of two alloys studied experimentally based on Taguchi method and response surface methodology. Taguchi’s L16 orthogonal array is used to design the experiment and a PVD (TiAlN), CVD (TiN/Al2O3/TiCN) coated carbide inserts are used on turning of two alloys. The factor effect on output responses are studied using analysis of variance, empirical models, and responses surface 3D plots. To minimize the response and to convert into one single optimum level, responses surface desirability function approach is applied. The results show that progress of flank wear associated with Waspaloy is faster that of Nimonic C-263 due to high cutting temperature for Waspaloy that…
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Fabrication and Machinability Study of Al2219 Metal Matrix Composites Reinforced with SiN/MoS2 Nanoparticles

Sri Sairam Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan, Devendiran Sundararajan, Akshay Seth, Navya Sood, Aditya Babu
  • Technical Paper
  • 2019-28-0170
To be published on 2019-10-11 by SAE International in United States
Composites materials are substituting constituents for traditional materials due to their remarkable properties, and the addition of nanoparticles gives a new development in the material domain. The nanoparticles influence on fabrication and machinability investigation study is essential as the composites to be used in applications like automotive and aerospace. The current study investigates the machinability characteristics of Al2219 based metal composites reinforced with nanoparticles of SiN/MoS2. Al2219- reinforcements (SiN and MoS2) composites are fabricated by the method of stir casting. Four different compositions (Al2219/SiN (2 wt% and 4 wt%), , Al2219/2 wt.% SiN/ 2 wt.% MoS2, Al2219/2 wt.% MoS2) are fabricated by varying the different weight percentages of nanoparticles reinforcements. An attempt is made to study the investigation analysis of force, surface roughness, and tool wear using CNC machine lathe to consider the effect of cutting speed, cutting depth, and samples. The machinability test is carried out, and the performance is compared. Addition of 2 wt% of SiN in Al2219 is to increase the hardness of nearly about 21%, 14%, 40% compared to that of…
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Experimental Investigation on Turning Characteristics of TiC/MoS2 Nanoparticles Reinforced Al7075 Using TiN Coated Cutting Tool

Sri Sairam Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan, Devendiran Sundararajan, Budireddy Uday Kumar, Dhulipalla Anvesh, Varupula Akhil
  • Technical Paper
  • 2019-28-0165
To be published on 2019-10-11 by SAE International in United States
In recent years, aluminum metal matrix composites (Al-MMC) are found as a potential material for numerous applications owing to its excellent tribological and mechanical properties. In this work, the machining characteristics of aluminum alloy (Al7075) reinforced with TiC/MoS2 having nanoparticle has been studied. The samples of aluminum metal matrix composites by varying TiC in 0, 2 and 4 and MoS2 in 0 and 2 of the percentage weight of aluminum alloy (Composite 1(Al7075), Composite 2 (Al7075/2TiC/2MoS2) and composite 3 (Al7075/4TiC/2MoS2), respectively) are fabricated by the stir-casing method. The turning characteristics of the developed metal matrix composites are studied at various parameters such as cutting velocity (30 m/min, 60 m/min and 90 m/min), cutting depth (0.5 mm, 1.0 mm and 1.5 mm) and composites (1, 2 and 3) using TiN coated cutting tool by dry turning at 0.05 mm/rev feed rate. The turning characteristics of the prepared samples are compared each other under L20 orthogonal array on CNC turning machine. The significant findings in the present study are: hardness of base aluminum alloy is found to…
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Empirical and Artificial Neural Network Modeling of Laser Assisted Hybrid Machining Parameters of Inconel 718 Alloy

Srisai Ram Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan
Published 2018-07-09 by SAE International in United States
In the present paper, to predict the process relation between laser-assisted machining parameters and machinability characteristics, statistical models are formulated by employing surface response methodology along with artificial neural network. Machining parameters such as speed of cut; the rate of feed; along with the power of laser are taken as model input variables. For developing confidence limit in collected raw experimental data, the full factorial experimental design was applied to cutting force; surface roughness; along with flank wear. Response surface method (RSM) with the least square method is used to develop the theoretical equation. Furthermore, artificial neural network method has been done to model the laser-assisted machining process. Then, both the models (RSM and ANN) are compared for accuracy regarding root mean square error (RMSE); model predicted error (MPE) along with the coefficient of determination (R2). The results show that the ANN model estimates the machinability indices with high accuracy that provides a maximum precision benefit range of about 10% - 22% than RSM model.
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Parametric Study, the Process Benefits, Optimization and Chip Morphology Study of Machining Parameter on Turning of Inconel 718 Using CVD Coated Tool and Nd: YAG Laser

Srisai Ram Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan
Published 2018-07-09 by SAE International in United States
This paper presents the parametric study, process benefits, optimization and chip appearance of machining parameters on turning of the Inconel 718 using Nd: YAG laser source. To analyze the mentioned above effect on alloy 718, the cutting inserts of chemical vapor disposition coated (CVD) TiN/TICN/Al2O3 are used to turn at the time of machining. To evaluate the linear (mean effect plots) and interaction effect (3D surface plots) of laser parameters on the force, roughness and tool wear to keep the minimal, experiments of the L27 orthogonal array are done by selecting the controllable parameters viz speed, the rate of feed along with laser power. From the parametric study, increase in speed and laser power along with decrement in the rate of feed resulted in lower cutting force. But surface finish and tool wear reduced with a decline in speed and scale of feed and increased with increment in laser power. The investigations result in shows that with the application of moderate laser power decline the cutting force by 28%; both surface roughness along with flank…
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A Comparative Study on Machinability Characteristics in Dry Machining of Inconel X-750 Alloy Using Coated Carbide Inserts

Srisai Ram Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan
Published 2018-07-09 by SAE International in United States
Nickel based superalloys have a wide range of applications due to high mechanical strength at high temperatures, fracture toughness and resistance to corrosion. However, because of their outstanding properties, it is considered as the difficult to machine materials. Inconel alloy X-750 is used extensively in rocket-engine thrust chambers. Airframe applications include thrust reversers and hot-air ducting systems along with large pressure vessels are formed from Inconel alloy X-750. Moreover, the comparative analysis of machinability aspect using coated carbide inserts is reported few. The current study explains the machinability investigation on Inconel alloy X-750 superalloys using coated carbides. To collect the experimental data, the L16 experimental design plan is used to experiment with a machining length of 40 mm. Four level of cutting speed (70,120,170,220 m/min), feed rate (0.1, 0.15, 0.2, 0.25 mm/rev) and cutting depth (0.3, 0.4, 0.5, 0.6 mm) are the cutting/machining parameters used. Cutting Forces, surface roughness, flank and crater wear are considered as target functions. With the application of response surface, coupled with desirability analysis, the optimal levels of the combination are…
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A Study on the Turning Characteristics and Optimization of MOS2p and SiCp-Reinforced Al-Si10Mg Metal Matrix Composites

Srisai Ram Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan
Published 2018-07-09 by SAE International in United States
In the fabrication of parts in auto and aero segments, the use of ceramic (SiCp, Al2O3p) reinforces aluminum alloy found to be increased than that of steel and cast iron. This matrix-reinforced alloy has a high strength to weight ratio along with higher modulus and hardness, the lower thermal coefficient of expansion, and improved tribological properties. To this extent, this paper investigates the turning characteristics and optimization study of newly developed metal matrix composites by the addition of both hard ceramic SiCp and soft stable lubricant molybdenum disulfide (MoS2p). The samples such as Sample 1: AlSi10Mg/3SiCp, Sample 2: AlSi10Mg/2MoS2p and Sample 3: AlSi10Mg/3SiCp /2MoS2p are prepared using the automated stir-casting machine. The particles are observed to be uniformly distributed in the composite. After density and hardness measurement, the samples are subjected to machining, and the responses are optimized by using response surface method. From the optimal points of investigation, the addition of MoS2P along with SiCp in sample 3 prevent the entrapment of hard particles in tool/workpiece interface for both sharp and dull thus tool…
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Design Optimization of an Epoxy Carbon Prepreg Drive Shaft and Design of a Hybrid Aluminium 6061-T6 Alloy/Epoxy Carbon Prepreg Drive Shaft

Srisai Ram Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan, Saketh Pemmasani
Published 2018-07-09 by SAE International in United States
Epoxy carbon fiber composite materials are known for their light weight and high performance. They can be effective substitutes for commonly used materials for making drive shafts. Fiber orientation angle plays a major role in determining such a drive shaft’s responses. The responses considered in this paper are critical buckling torque, fundamental natural frequency and total deformation. A drive shaft made of epoxy carbon unidirectional prepreg is generated using ANSYS 18.0 ACP Composite Prepost. The objective of this paper is to determine an optimal configuration of fiber orientation angles for four, five and six-layered epoxy carbon drive shaft which tends to increase critical buckling torque and fundamental natural frequency while decreasing the total deformation. The optimal configuration which satisfies this objective for the three responses is identified by Minitab 17 statistical software. The effect of fiber orientation angle with respect to each of these responses is studied in detail. Finally, a hybrid shaft is considered with aluminium 6061-T6 alloy tube on the exterior and 4 layers of epoxy carbon layers stacked up in optimal configuration…
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