Skip to main content
SpringerLink
Log in

Inconel 718 machining performance evaluation using indigenously developed hybrid machining facilities: experimental investigation and sustainability assessment

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

To improve the machinability of Inconel 718, a lot of work has been done in the past decade by modifying tools and machining processes. However, a recently developed cryogenic-ultrasonic assisted turning (CUAT) process influencing the machinability of Inconel 718 as compared to the conventional turning process (CT) has not been conspicuously presented. This paper analyzes the machinability of Inconel 718 using indigenously developed ultrasonic assisted turning (UAT) and CUAT facilities. The influence of the UAT process of Inconel 718 on cutting parameters recommended by the industry has been investigated. Surface roughness (Ra) and power consumption are measured under the UAT process and then compared with the CT process. Particle swarm optimization (PSO) algorithm is used to identify the optimum cutting parameters to achieve minimum Ra and power consumption for UAT and CT processes. The optimized parameters are considered to confirm the usefulness of CUAT as compared to UAT and CT processes. Experimental results of this research work endorse positive effects of the CUAT process over UAT and CT processes in terms of Ra and chip morphology. Ra values under the CUAT process are reduced significantly in comparison to UAT and CT processes, respectively. UAT and CUAT processes resulted in discontinuous chips having smaller chip thickness in comparison to the CT process. The results are being shared with the local SMEs, and the industry is anticipated to be benefited in terms of improving cutting performance using CUAT and UAT. Moreover, a sustainability assessment model is implemented to investigate the effect of CUAT in terms of machining performance as well as sustainability effectiveness in a single integrated approach.

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

Similar content being viewed by others

Abbreviations

CT :

Conventional turning

UAT :

Ultrasonic assisted turning

CUAT :

Cryogenic-ultrasonic assisted turning

v c :

Cutting speed in m/min

f r :

Feed in mm/rev

f :

Frequency in kHz

a p :

Depth of cut in mm

R a :

Average surface roughness in μm

DoE :

Design of experiments

rpm :

Revolutions per minute

LN 2 :

Liquid nitrogen

TWCR :

Tool-workpiece contact ratio

TWSI :

Total weighted sustainable index

References

  1. Anbarasan N, Jerome S, Suresh G, Oyyaravelu R (2019) Effect of pulse frequency on microstructural and corrosion properties of Inconel 718 gas tungsten arc weldments. Trans Indian Inst Metals 72(5):1299–1311

    Article  Google Scholar 

  2. Wang X, Huang C, Zou B, Liu G, Zhu H, Wang J (2018) Experimental study of surface integrity and fatigue life in the face milling of Inconel 718 front. Mech Eng 13:243–250

    Google Scholar 

  3. Thirumalai R, Senthilkumar JS (2013) Multi-criteria decision making in the selection of machining parameters for Inconel 718. J Mech Sci Technol 27(4):1109–1116

    Article  Google Scholar 

  4. Akhtar W, Sun J, Sun P, Chen W, Saleem Z (2014) Tool wear mechanisms in the machining of nickel based super-alloys : a review front. Mech Eng 9:106–119

    Google Scholar 

  5. Shokrani A, Dhokia V, Newman ST, Imani-Asrai R (2012) An initial study of the effect of using liquid nitrogen coolant on the surface roughness of Inconel 718 nickel-based alloy in CNC milling. Procedia CIRP 3(1):121–125

    Article  Google Scholar 

  6. 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(7–8):931–942

    Article  Google Scholar 

  7. Silberschmidt VV, Mahdy SMA, Gouda MA, Naseer A, Maurotto A, Roy A (2014) Surface-roughness improvement in ultrasonically assisted turning. Procedia CIRP 13:49–54

    Article  Google Scholar 

  8. Xu S, Kuriyagawa T, Shimada K, Mizutani M (2017) Recent advances in ultrasonic-assisted machining for the fabrication of micro/nano-textured surfaces front. Mech Eng 12:33–45

    Google Scholar 

  9. Sharma V, Pandey PM (2016) Recent advances in ultrasonic assisted turning: a step towards sustainability. Cogent Eng 3(1):1–20

    Google Scholar 

  10. Wang Q, Wu Y, Gu J, Lu D, Ji Y, Nomura M (2016) Fundamental machining characteristics of the in-base-plane ultrasonic elliptical vibration assisted turning of Inconel 718. Procedia CIRP 42:858–862

    Article  Google Scholar 

  11. Maurotto A, Muhammad R, Roy A, Babitsky VI, Silershmidt VV (2012) Comparing machinability of Ti-15-3-3-3 and Ni-625 alloys in Uat. Procedia CIRP 1:330–335

    Article  Google Scholar 

  12. Muhammad R, Ahmed N, Roy A, Silberschmidt VV 2012 Turning of advanced alloys with vibrating cutting tool. In: Solid State Phenomena. Trans Tech Publ., 277–284

  13. Chen DY, Tsao CC, Lin MY, Tsai CH, Hsu CY 2012 Ultrasonic-assisted on the turning of Inconel 718 by Taguchi method. In: Advanced Materials Research. Trans Tech Publ., 160–73

  14. Lin SY, Chung CT, Cheng YY 2011 Combination of ultrasonic vibration and cryogenic cooling for cutting performance improvement of Inconel 718 turning. In: AIP Conference Proceedings, 1163–1168

  15. Nath C, Rahman M (2008) Effect of machining parameters in ultrasonic vibration cutting. Int J Mach Tools Manuf 48(9):965–974

    Article  Google Scholar 

  16. Ahmed N, Mitrofanov AV, Babitsky VI, Silberschmidt VV (2006) Analysis of material response to ultrasonic vibration loading in turning Inconel 718. Mater Sci Eng A 424(1–2):318–325

    Article  Google Scholar 

  17. Xavior MA, Patil M, AbheekMaiti RM, Lohia N (2016) Machinability studies on INCONEL 718. IOP Conf Ser Mater Sci Eng 149:12–19

    Article  Google Scholar 

  18. Bhanot N, Rao PV, Deshmukh SG (2015) Sustainable manufacturing: an interaction analysis for machining parameters using graph theory. Procedia Soc Behav Sci 189:57–63

    Article  Google Scholar 

  19. Pusavec F, Deshpande A, Yang S, M’Saoubic R, Kopac J, Jawahir IS (2015) Sustainable machining of high temperature nickel alloy – Inconel 718: part 2 – chip breakability and optimization. J Clean Prod

  20. Khanna N, Agrawal C, Joshi V 2017 Zero vapor loss integrated cryogen phase separator. Indian Patents, 201721031291 A

  21. Musfirah AH, Ghani JA, Haron CC (2017) Tool wear and surface integrity of Inconel 718 in dry and cryogenic coolant at high cutting speed. Wear 376–377:125–133

    Article  Google Scholar 

  22. Khanna N, Suri N, Agrawal C, Shah P, Krolczyk GM (2019) Effect of hybrid machining techniques on machining performance of in-house developed mg-PMMC. Trans Indian Inst Metals

  23. Khanna N (2016) Design of experiments in titanium metal cutting research. In: Design of experiments in production engineering. Springer, Cham, pp 165–182

    Chapter  Google Scholar 

  24. Khanna N, Davim JP (2015) Design-of-experiments application in machining titanium alloys for aerospace structural components. Meas J Int Meas Confed 61:280–290

    Article  Google Scholar 

  25. Krishnaiah K, Shahabudeen P (2012) Applied design of experiments and Taguchi methods. PHI Learning Pvt Ltd., New Delhi

    Google Scholar 

  26. Cartigueyen S, Mahadevan K (2019) Effects of thermal conditions on microstructure and mechanical properties of cu–SiCp surface nanocomposites by friction stir processing route. Trans Indian Inst Metals 72(2):289–305

    Article  Google Scholar 

  27. Gupta MK, Sood PK, Sharma VS (2016) Optimization of machining parameters and cutting fluids during nano-fluid based minimum quantity lubrication turning of titanium alloy by using evolutionary techniques. J Clean Prod 135:1276–1288

    Article  Google Scholar 

  28. Chen X, Wang S, Qiao B, Chen Q (2018) Basic research on machinery fault diagnostics : past, present, and future trends front. Mech Eng 13:264–291

    Google Scholar 

  29. Pusavec F, Hamdi H, Kopac J, Jawahir IS (2011) Surface integrity in cryogenic machining of nickel based alloy—Inconel 718. J Mater Process Technol 211(4):773–783

    Article  Google Scholar 

  30. Kaynak Y, Karaca HE, Noebe RD, Jawahir IS (2013) Tool-wear analysis in cryogenic machining of NiTi shape memory alloys : a comparison of tool-wear performance with dry and MQL machining. Wear 306:51–63. https://doi.org/10.1016/j.wear.2013.05.011

    Article  Google Scholar 

  31. Kumar R, Sahoo AK, Mishra PC et al (2018) Adv Manuf 6:52. https://doi.org/10.1007/s40436-018-0215-z

    Article  Google Scholar 

  32. Sahoo AK, Sahoo AK, Mohanty T et al (2013) Optimization of multiple performance characteristics in turning using Taguchi’s quality loss function: an experimental investigation. Int J Ind Eng Comput 4(3):325–336

    Google Scholar 

  33. Khanna N, Agrawal C, Gupta MK, Song Q (2019) Tool wear and hole quality evaluation in cryogenic drilling of Inconel 718 superalloy. Tribol Int. https://doi.org/10.1016/j.triboint.2019.106084

    Article  Google Scholar 

  34. Merchant ME (1945) Mechanics of the metal cutting process. I. Orthogonal cutting and a type 2 chip. J Appl Phys 16(5):267–275

    Article  Google Scholar 

  35. Molinari A, Musquar C, Sutter G (2002) Adiabatic shear banding in high speed machining of Ti – 6Al – 4V : experiments and modeling. Int J Plast 18:443–459

    Article  Google Scholar 

  36. Kaynak Y (2014) Evaluation of machining performance in cryogenic machining of Inconel 718 and comparison with dry and MQL machining. https://doi.org/10.1007/s00170-014-5683-0

    Article  Google Scholar 

  37. Taylor P, Machining F, Kaynak Y, Lu T, Jawahir IS. Machining science and technology : an cryogenic machining-induced surface integrity : a review and comparison with n.d.:37–41

  38. Hegab HA, Darras B, Kishawy HA (2018) Towards sustainability assessment of machining processes. J Clean Prod 170:694–703

    Article  Google Scholar 

  39. Narita H, Desmira N, Fujimoto H (2008) Environmental burden analysis for machining operation using LCA method. In: Manufacturing Systems and Technologies for the New Frontier. Springer, London, pp 65–68

    Chapter  Google Scholar 

Download references

Acknowledgments

The authors are thankful to the SERB-DST, Government of India, for providing financial aid under the project no. ECR/2016/000735, titled “Design and Development of Energy Efficient Cryogenic Machining Facility for Heat Resistant Alloys and Carbon Fibre Composites”. The authors also acknowledge the assistance of Mr. Jay Airao during experimentation.

Author information

Authors and Affiliations

  1. Institute of Infrastructure Technology Research and Management, Ahmedabad, 380026, India

    Navneet Khanna, Prassan Shah & Chetan Agrawal

  2. Faculty of Mechanical Engineering, University of Ljubljana, Askerceva 6, 1000, Ljubljana, Slovenia

    Franci Pusavec

  3. Mechanical Design and Production Engineering Department, Cairo University, Giza, 12613, Egypt

    Hussien Hegab

Authors
  1. Navneet Khanna
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Prassan Shah
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chetan Agrawal
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Franci Pusavec
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Hussien Hegab
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hussien Hegab.

Additional information

Publisher’s note

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

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Khanna, N., Shah, P., Agrawal, C. et al. Inconel 718 machining performance evaluation using indigenously developed hybrid machining facilities: experimental investigation and sustainability assessment. Int J Adv Manuf Technol 106, 4987–4999 (2020). https://doi.org/10.1007/s00170-020-04921-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-04921-x

Keywords

Search

Navigation