Manufacturing Technology Today

B. Satyanarayana ¹, G. Ranga Janardhana ², D. Hanumantha Rao ³

Affiliations
1 Dept. of Mechanical Engg., VNR Vignana Jyothi Institute of Engg. & Technology, Hyderabad, IN
2 College of Engg., JNTU, Vizayanagaram, IN
3 Dept. of Mechanical Engg., MVSR Engineering College, Hyderabad, IN

Abstract

Inconel 718 is one of the most difficult-to-cut materials because of its low thermal diffusive property, high hardness, and high strength at high temperature. This paper presents a hybrid optimization approach for determination of the optimum turning process parameters (speed, feed and depth of cut) which minimize the Surface Roughness (SR) and maximize Metal Removal Rate (MRR) together in CNC high speed turning of Inconel 718 nickel based super alloy with uncoated tungsten carbide cutting tool. A multi-response optimization has been carried out by using Taguchi method based Grey Relational Analysis (GRA). Also the significant process parameters have been found out for the above process optimization by performing an ANOVA. Confirmation tests with the optimal levels of cutting parameters are carried out in order to illustrate the effectiveness of the method. Validations of the modeled equations are proved to be well within the agreement with the experimental data.

Keywords

Inconel 718, Multi-Response Optimization, Grey Relational Analysis, Taguchi Method, ANOVA.

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D. Hanumantha Rao ¹, G. R. N. Tagore ², G. Rangajanardhan ³

Affiliations
1 Mechanical Engg. Dept., Deccan College of Engineering & Technology, Hyderabad, IN
2 Mechanical Engg. Dept., National Institute of Technology, Warangal, IN
3 Mechanical Engg. Dept., Jawaharlal Nehru Technological University, Hyderabad, IN

Abstract

Integrating statistical techniques and simulation technologies and their simultaneous usage allow shortest product development periods, required casting quality, on the whole, improves economic efficiency. Casting solidification simulations are conducted for a stepped block of aluminum alloy casting to study the effect of pouring temperature and chill parameters on porosity formation and cooling rate in a sand casting. Taguchi methods are used for experimental simulations with a four factor, three level L9 orthogonal array. Porosity and cooling rate are recorded from a three-dimensional finite difference solidification simulation program as response functions. Statistical techniques are used for analyzing the effect of process parameters on porosity and cooling rate In the cast component. Numerical optimization techniques are presented with multivariable optimization for predicting the factor levels for minimization of porosity and maximization of cooling rate. A confirmation run is carried out to compare the predicted levels of process parameters with final simulation run.

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