Manufacturing Technology Today

J. S. Senthilkumaar ¹, P. Asokan ², R. M. Arunachalam ¹

Affiliations
1 Dept. of Mechanical Engg., Sona College of Technology, Salem, IN
2 Dept. of Production Engg., National Institute of Technology, Tiruchirapalli, IN

Abstract

Selection of machining parameters is a very important task to the process planer to achieve desired surface roughness with minimum machining cost. Facing operation is an important and inevitable machining process for manufacture of aero space components like disks and blades. The cutting tool manufacturer's recommended cutting parameters are usually for turning operation and common for few materials and so adapting their turning conditions for facing process results in premature tool failure and poor surface finish. Based on the machining experience and earlier research results, uncoated tools performance are better than the coated tools and necessity to control the pollution dry machining are preferred. In this paper, the surface roughness and tool wear when facing Inconel 718 using uncoated carbide cutting tools have been investigated. The results show that the feed and cutting speed were the most influential factors on the surface roughness and flank wear. The optimum machining parameters are predicted for minimization of surface roughness and minimization of tool wear by simultaneously optimized. The predicted results have good agreements with experimental results.

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J. S. Senthilkumaar ¹, R. Saravanan ¹, P. Asokan ²

Affiliations
1 Dept of Mechatronics Engg., Kumaraguru College of Technology, Coimbatore, IN
2 Dept of Production Engg., National Institute of Technology, Tiruchirapalli, IN

Abstract

Determination of cutting parameters for tough and hard material is very important for the process planner to achieve the economic machining process. The paper proposes a new optimization technique based on genetic algorithms (GA) to optimize the objectives like minim.um surface roughness, power required and cutting force and maximum tool life. Many researchers concentrate the single objective to optimize the process parameters, this paper presents a new methodology to optimize the process parameters for each objective each time one objective will optimize and other objective will be treated as constraints. Experimental results proved that the effectiveness of proposed genetic algorithm based multiple optimizations solving this machining problem.

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J. S. Senthilkumaar ¹, P. Selvarani ², I. Arun ¹, S. Thamizhmanii ¹

Affiliations
1 Department of Mechanical Engineering, Madanapalle Institute of Technology & Science, Madanapalle, IN
2 Department of Mechanical Engineering, Government Polytechnic College, Dharmapuri, IN

Abstract

The machinability assessment is the critical and challenging task for machining of heat resistant super alloy material like Inconel 718. In finish turning operations are very important in order assemble the component made of such difficult to machining materials. The high speed finish turning process has been carried out with uncoated carbide inserts are used with cold coolant machining conditions. This paper describes an intelligent interactive model development using the machining responses like tool life, surface roughness, and cutting force for high speed finish turning Inconel 718 by using response surface methodology. Based on the design of experiments finish turning trials are conducted at three levels of cutting parameters cutting speed, feed and depth of cut in low, medium and high. Tool life and surface roughness, and cutting force, which are the major aspects of machinability, have been discussed in this investigation. The interactive response optimizer has been developed for intelligent decision making also demonstrated the selection of process parameters against the multi response requirements.

Keywords

Response Optimizer. Inconel 718, Finish Turning, High Speed Machining, Surface Roughness, Cutting Force, Tool Wear.

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