Skip to main content
SpringerLink
Log in

Finite Element Modeling and Experimental Validation of Tool Wear in Hot-Ultrasonic-Assisted Turning of Nimonic 90

  • Original Paper
  • Published:
Journal of Vibration Engineering & Technologies Aims and scope Submit manuscript

Abstract

Purpose

Repetitive cutting nature of ultrasonic-assisted turning (UAT) has evidenced considerable enhancements in the machinability of difficult-to-cut materials. Pre-heating is another approach for improving the machinability of such materials. In this regard, a novel approach, combining ultrasonic vibration and pre-heating of a workpiece, is proposed to analyze the responses while cutting difficult-to-cut material. Thus, this study aims to develop a finite element (FE) model to estimate tool wear, chip–tool contact length and machining forces, under the combined effect, considering Nimonic 90 as workpiece material. The FE results are validated using an in-house developed setup.

Methods

The finite element model is developed for executing conventional turning (CT), UAT, and hot-UAT (HUAT) at 200 °C. The resonance frequency and amplitude used are 20 kHz and 10 µm, respectively, for the UAT and HUAT processes. Moreover, the horn is designed using FEM and fabricated to develop the UAT setup. The turning experiments of all three types are performed for Nimonic 90 under dry conditions at two different sets of process parameters. The induction heating technique is used for the HUAT to pre-heat the workpiece to maintain similar initial conditions as the FEM. The tool flank and crater wear, machining forces, and tool–chip contact length estimated by FEM are validated using the UAT setup.

Results

The results are examined in terms of tool flank and crater wear, tool–chip contact length, cutting force, and feed forces. The FEM and experimental results are found to be in close agreement with an approximate error of 2–25%. The main tool wear mechanisms detected are edge chipping, abrasion, adhesion of BUE, and fracture of tool nose. The HUAT reduces the tool–chip contact length by 5–21%, cutting force by 5–25%, and feed force by 14–36%, compared to CT and UAT. It is also observed that the error increases at the higher value of cutting speed. It is attributed to a catastrophic failure of the cutting edge at a higher cutting speed.

Conclusion

The HUAT and UAT show a substantial reduction in tool wear while machining at a low cutting speed. Whereas, at a higher cutting speed, the tool wear significantly increases in all three types of turning operations.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig.4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

Abbreviations

σ:

Flow stress of workpiece material (MPa)

\({\sigma }_{1}\) :

Maximum principal stress (MPa)

\({\sigma }_{f}\) :

Flow stress (MPa)

\({\sigma }_{n}\) :

Contact pressure at tool–chip interface (MPa)

\({\sigma }_{nn}\) :

Normal stress (MPa)

ɛ:

Plastic strain

\({\upvarepsilon }_{f}\) :

Effective strain

\(\dot{\varepsilon }\) :

Strain rate (s−1)

\(\dot{{\varepsilon }_{0}}\) :

Reference strain rate (s−1)

\(\eta\) :

Speed of sound through solid (m/s)

τ:

Frictional shear stress (MPa)

µ:

Coefficient of friction

\(\omega\) :

Angular frequency (rad)

λ:

Frequency of the wave (rad/s)

\(a\) :

Amplitude (µm)

\({a}_{p}\) :

Depth of cut (mm)

\(f\) :

Frequency (Hz)

\(h\) :

Heat convection coefficient (W/m2 °C)

\({h}_{p}\) :

Heat transfer coefficient at processing zone

\(m\) :

Thermal softening coefficient

\({m}_{f}\) :

Constant of shear friction

\(n\) :

Hardening coefficient

\({q}_{t}\) :

Heat flux at tool–environment interface

\({q}_{w}\) :

Heat flux at workpiece–environment interface

s:

Velocity of pressure wave (m/s)

\(t\) :

Time (s)

\({t}_{0}\) :

Uncut chip thickness (mm)

\(w\) :

Crater wear (mm)

\(A\) :

Yield strength of workpiece material (MPa)

\({A}_{h}\) :

Cross section of the solid bar (mm2)

\(B\) :

Hardening modulus (MPa)

\(C\) :

Strain rate sensitivity coefficient

\(D\) :

Material constant for damage

\(F\) :

Feed rate (mm/rev)

\({F}_{c}\) :

Cutting force (N)

\({F}_{f}\) :

Feed force (N)

\({L}_{c}\) :

Tool–chip contact length (mm)

\(T\) :

Workpiece temperature (°C)

\({T}_{0}\) :

Room temperature (°C)

\({T}_{i}\) :

Temperature at tool–chip interface (°C)

\({T}_{m}\) :

Melting temperature of workpiece material (°C)

\({T}_{t}\) :

Tool temperature (°C)

\({T}_{w}\) :

Workpiece temperature (°C)

\(V\) :

Cutting speed (m/min)

\({V}_{s}\) :

Sliding velocity at tool–chip interface (m/min)

\({V}_{t}\) :

Velocity given to the cutting tool (m/min)

VB :

Width of flank wear (mm)

CT:

Conventional turning

JC:

Johnson–Cook

WC:

Tungsten carbide

BUE:

Built-up edge

CVD:

Chemical vapor deposition

FEM:

Finite element modeling

SEM:

Scanning electron microscopy

UAT:

Ultrasonic-assisted turning

HUAT:

Hot ultrasonic-assisted turning

TWCR:

Tool–workpiece contact ratio

References

  1. Choudhury IA, El-Baradie MA (1998) Machinability of nickel-base super alloys: a general review. J Mater Process Technol 77(1–3):278–284

    Google Scholar 

  2. Thakur A, Gangopadhyay S (2016) State-of-the-art in surface integrity in machining of nickel-based super alloys. Int J Mach Tools Manuf 100:25–54

    Google Scholar 

  3. Khanna N, Airao J, Gupta MK, Song Q, Liu Z, Mial M, Maruda R, Krolczyk G (2019) Optimization of power consumption as-sociated with surface roughness in ultrasonic assisted turning ofNimonic-90 using hybrid particle swarm-simplex method. Materials 12:3418

    Google Scholar 

  4. Dandekar CR, Shin YC (2010) Laser-assisted machining of a fiber reinforced metal matrix composite. ASME J Manuf Sci Eng 132(6):061004

    Google Scholar 

  5. Choi YH, Lee CM (2018) A study on the machining characteristics of AISI 1045 steel and Inconel 718with circular cone shape in induction assisted machining. J Manuf Process 34:463–476

    Google Scholar 

  6. Najiha MS, Rahman MM, Yusoff AR (2015) Flank wear characterization in aluminum alloy (6061 T6) with nanofluid minimum quantity lubrication environment using an uncoated carbide tool. ASME J Manuf Sci Eng 137(6):061004

    Google Scholar 

  7. Nath C, Rahman M (2008) effect of machining parameters in ultrasonic vibration cutting. Int J Mach Tools Manuf 48:965–974

    Google Scholar 

  8. Airao J, Khanna N, Roy A, Hegab H (2020) Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility. Int J Adv Manuf Technol 109:1447–1462

    Google Scholar 

  9. Airao J, Nirala CK (2022) Machinability of Ti-6Al-4V and Nimonic-90 in ultrasonic-assisted turning under sustainable cutting fluid. Mater Today Proc. https://doi.org/10.1016/j.matpr.2022.02.312

    Article  Google Scholar 

  10. Airao J, Nirala CK, Lacalle LNdL, Khanna N (2021) Tool wear analysis during ultrasonic assisted turning of Nimonic-90 under dry and wet conditions. Metals 11(8):1253

    Google Scholar 

  11. Woo WS, Lee CM (2019) Innovative use of multi-heat sources for improvement of tool life in thermally assisted machining of high-strength material. J Manuf Process 38:30–37

    Google Scholar 

  12. Kim JH, Kim EJ, Lee CM (2020) A study on the heat affected zone and machining characteristics of difficult to-cut materials in laser and induction assisted machining. J Manuf Process 57:499–508

    Google Scholar 

  13. Gholamzadeh B, Soleimanimehr H (2019) Finite element modeling of ultrasonic-assisted turning: cutting force and heat generation. Mach Sci Technol 23(6):869–885

    Google Scholar 

  14. Ahmed N, Mitrofanov AV, Babitsky VI, Silberschmidt VV (2007) 3D finite element analysis of ultrasonically assisted turning. Comp Mater Sci 39(1):149–154

    Google Scholar 

  15. Muhammad R, Maurotto A, Demiral M, Roy A, Silberschmidt VV (2014) Thermally enhanced ultrasonically assisted machining of Ti alloy. CIRP J Manuf Sci Technol 7(2):159–167

    Google Scholar 

  16. Airao J, Nirala CK (2021) Finite element modeling of ultrasonic assisted turning with external heating. Proc CIRP 102:61–66

    Google Scholar 

  17. Lotfi M, Jahanbakhsh M, Farid AA (2016) Wear estimation of ceramic and coated carbide tools in turning of Inconel 625: 3D FE analysis. Trib Int 99:107–116

    Google Scholar 

  18. Attanasio A, Cerettin E, Rizzuti S, Umbrello D, Micari F (2008) 3D finite element analysis of tool wear in machining. CIRP Ann: Manuf Technol 57:61–64

    Google Scholar 

  19. Malakizadi A, Gruber H, Sadik I, Nyborg L (2016) An FEM-based approach for tool wear estimation in machining. Wear 368–369:10–24

    Google Scholar 

  20. Khajehzadeh M, Boostanipour O, Razfar MR (2020) Finite element simulation and experimental investigation of residual stresses in ultrasonic assisted turning. Ultrasonics 108:106208

    Google Scholar 

  21. Thanh CL, Nguyen TN, Vu TH, Khatir S, Wahab MA (2022) A geometrically nonlinear size-dependent hypothesis for porous functionally graded micro-plate. Eng Comp 38(1):S449–S460

    Google Scholar 

  22. Phung-Van P, Thai CH, Xuan HN, Wahab MA (2019) An isogeometric approach of static and free vibration analyses for porous FG nanoplates. Euro J Mech A: Solids 78:103851

    MathSciNet  MATH  Google Scholar 

  23. Thanh CL, Hoang LM, Phuong PV, Phuoc NT, Tounsi A (2022) Nonlinear bending analysis of porous sigmoid FGM nanoplate via IGA and nonlocal strain gradient theory. Adv Nano Res 12(5):441–455

    Google Scholar 

  24. Thanh CL, Tran LV, Huu TV, Wahab MA (2019) The size-dependent thermal bending and buckling analyses of composite laminate microplate based on new modified couple stress theory and isogeometric analysis. Comput Methods Appl Mech Eng 350:337–361

    MathSciNet  MATH  Google Scholar 

  25. Thanh CL, Nguyen KD, Le MH, To TS, Vu PP, Wahab MA (2022) Nonlocal strain gradient IGA numerical solution for static bending, free vibration and buckling of sigmoid FG sandwich nanoplate. Physica B: Cond Matt 631:413426

    Google Scholar 

  26. Vinh PV, Chinh NV, Tounsi A (2022) Static bending and buckling analysis of bi-directional functionally graded porous plates using an improved first-order shear deformation theory and FEM. Euro J Mech A: Solids 96:104743

    MathSciNet  MATH  Google Scholar 

  27. Kumar Y, Gupta A, Tounsi A (2021) Size-dependent vibration response of porous graded nanostructure with FEM and nonlocal continuum model. Adv Nano Res 11(1):01–17

    Google Scholar 

  28. Alimirzaei S, Mohammadimehr M, Tounsi A (2019) Nonlinear analysis of viscoelastic micro-composite beam with geometrical imperfection using FEM: MSGT electro-magneto-elastic bending, buckling and vibration solutions. Struct Eng Mech 71(5):485–502

    Google Scholar 

  29. Garg A, Belarbi MO, Tounsi A, Li L, Singh A, Mukhopadhyay T (2022) Predicting elemental stiffness matrix of FG nanoplates using Gaussian Process Regression based surrogate model in framework of layerwise model. Eng Ana Bound Elem 143:779–795

    MathSciNet  MATH  Google Scholar 

  30. Markopoulos AP (2013) Finite element method in machining processes. Springer

    Google Scholar 

  31. Xi Y, Bermingham M, Wang G, Dargusch M (2013) Finite element modeling of cutting force and chip formation during thermally assisted machining of Ti6Al4V alloy. ASME J Manuf Sci Eng 135(6):061014

    Google Scholar 

  32. Johnson GR, Cook WH (1983) A Constitutive Model and Data for Metals. Proceedings of the Seventh International Symposium on Ballistics, The Hague, The Netherlands, April 19–21: 541–547.

  33. Cockroft MG, Latham DJ (1968) Ductility and workability of metals. J Inst Met 96:33–39

    Google Scholar 

  34. Umbrello D (2008) Finite element simulation of conventional and high-speed machining of Ti6Al4V alloy. J Mater Process Technol 196:79–87

    Google Scholar 

  35. Chetan GS, Rao PV (2018) Specific cutting energy modeling for turning nickel-based Nimonic 90 alloy under MQL condition. Int J Mech Sci 146–147:25–38

    Google Scholar 

  36. Airao J, Nirala CK (2021) Analytical modeling of machining forces and friction characteristics in ultrasonic assisted turning process. ASME J Manuf Sci Eng 144(2):021014

    Google Scholar 

  37. Yen YC, Jain A, Altan T (2004) A finite element analysis of orthogonal machining using different tool edge geometries. J Mater Process Technol 146(1):72–81

    Google Scholar 

  38. Ozel T (2006) The influence of friction models on finite element simulations of machining. Int J Mach Tools Manuf 46:518–530

    Google Scholar 

  39. Usui E, Shirakhashi T, Kitagawa T (1978) Part: 3 analytical prediction of three dimensional cutting process. Trans ASME: J Eng Ind 1:33–38

    Google Scholar 

  40. Airao J, Kishore H, Nirala CK (2021) Tool wear behavior in μ-turning of nimonic 90 under vegetable oil-based cutting fluid. ASME J Micro Nano-Manuf, DOI 10(1115/1):4053315

    Google Scholar 

  41. Stephenson DA, Agapiou JS (1997) Metal cutting theory and practice. CRC Press

    Google Scholar 

  42. Choi YH, Lee CM (2018) A study on the machining characteristics of AISI 1045 steel and Inconel 718 with circular cone shape in induction assisted machining. J Manuf Process 34:464–476

    Google Scholar 

  43. Airao J, Nirala CK (2022) Machinability analysis of Titanium-64 using ultrasonic vibration and vegetable-oil. Mater Manuf Process 37(16):1893–1901

    Google Scholar 

  44. Trent EM, Wright PK (2000) Metal Cutting, Butterworth-Heinemann. Elsevier, Amsterdam, The Netherlands

    Google Scholar 

  45. Ezugwu EO, Wang ZM, Machado AR (1999) The machinability of Nickel-based alloys: a review. J Mater Process Technol 86:1–16

    Google Scholar 

  46. Ozler L, Inan A, Ozel C (2001) Theoretical and experimental determination of tool life in hot machining of austenitic manganese steel. Int J Mach Tools Manuf 41:163–172

    Google Scholar 

  47. Airao J, Nirala CK, Bertolini R, Krolczyk GM, Khanna N (2022) Sustainable cooling strategies to reduce tool wear, power consumption and surface roughness during ultrasonic assisted turning of Ti-6Al-4V. Tribo Int 169:107494

    Google Scholar 

  48. Zhu D, Zhang X, Ding H (2013) Tool wear characteristics in machining of Nickel-based superalloys. Int J Mach Tools Manuf 64:60–77

    Google Scholar 

  49. Devillez A, Schneider F, Dominiak S, Dudzinski D, Larrouquere D (2007) Cutting forces and wear in dry machining of Inconel 718 with coated carbide tools. Wear 262:931–942

    Google Scholar 

  50. Ambhore N, Kamble D, Agrawal D (2022) Experimental investigation of induced tool vibration in turning of hardened AISI52100 steel. J Vib Eng Technol. https://doi.org/10.1007/s42417-022-00473-4

    Article  Google Scholar 

  51. Chetan BBC, Ghosh S, Rao PV (2016) Wear behaviour of PVD TiN coated carbide inserts during machining of Nimonic 90 and Ti6Al4V superalloys under dry and MQL conditions. Cera Int 42:14873–14885

    Google Scholar 

  52. Bermingham MJ, Oalanisamy S, Dargusch MS (2012) Understanding the tool wea mechanism during thermally assisted machining Ti-6Al-4V. Int J Mach Tools Manuf 62:76–87

    Google Scholar 

Download references

Funding

No funding was received for conducting this study.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab, 140001, India

    Jay Airao & Chandrakant K. Nirala

Authors
  1. Jay Airao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Chandrakant K. Nirala
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Chandrakant K. Nirala.

Ethics declarations

Conflict of Interest

The authors have no relevant financial or non-financial interests to disclose.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Airao, J., Nirala, C.K. Finite Element Modeling and Experimental Validation of Tool Wear in Hot-Ultrasonic-Assisted Turning of Nimonic 90. J. Vib. Eng. Technol. 11, 3687–3705 (2023). https://doi.org/10.1007/s42417-022-00776-6

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s42417-022-00776-6

Keywords

Search

Navigation