Abstract
Knowledge of material removal behavior and generated surface characteristics are crucial to improve grinding performance. A finite element model was developed using a single grit approach with the consideration of uncut chip thick variations along the grain path. It was found that the increase in cutting speed and the decrease in rake angle led to the generation of discontinuous chips in adiabatic shearing conditions. Besides, the larger shear stresses induced by friction in the grain-chip interface contributed to the formation of chips with larger discontinuities. The enlargement of subsurface damage (SSD) depth by 23.86% and 129.42% was caused by the increase in grain edge radius from 0.5 to 2.5 μm and the rise in maximum uncut chip thickness from 0.5 to 1.5 μm, respectively. However, the SSD depth firstly decreased, and then increased with the approach to more negative rake angles and larger cutting speeds. A multi-response optimization based on analysis of variance (ANOVA) and SSD predictive model calculated the optimum combination of influential parameters as maximum uncut chip thickness of 0.719 μm, cutting speed of 80 m/s, cutting edge radius of 0.5 μm, and rake angle of − 30°. This led to the minimum SSD depth of 0.406 μm and the maximum removal rate of 57.493 mm3/mm s. The experimental results confirmed the positive contribution of an eco-friendly nanofluid minimum quantity lubrication (NMQL), containing graphene nanoplatelets with 0.3 wt% concentration within the green nanofluid, to the significant improvement of surface roughness (by 41.09%, relative to dry grinding) and morphology.
Similar content being viewed by others
References
Hosseini E, Popovich VA (2019) A review of mechanical properties of additively manufactured Inconel 718. Addit Manuf 30:100877. https://doi.org/10.1016/j.addma.2019.100877
Nnaji RN, Bodude MA, Osoba LO, Fayomi OSI, Ochulor FE (2020) Study on high-temperature oxidation kinetics of Haynes 282 and Inconel 718 nickel-based superalloys. Int J Adv Manuf Technol 106:1149–1160. https://doi.org/10.1007/s00170-019-04290-0
Qian N, Ding W, Zhu Y (2018) Comparative investigation on grindability of K4125 and Inconel718 nickel-based superalloys. Int J Adv Manuf Technol 97:1649–1661. https://doi.org/10.1007/s00170-018-1993-y
D’Addona DM, Raykar SJ (2019) Thermal modeling of tool temperature distribution during high pressure coolant assisted turning of Inconel 718. Mater (Basel, Switzerland) 12:408. https://doi.org/10.3390/ma12030408
Li B, Ding W, Yang C, Li C (2019) Grindability of powder metallurgy nickel-base superalloy FGH96 and sensibility analysis of machined surface roughness. Int J Adv Manuf Technol 101:2259–2273. https://doi.org/10.1007/s00170-018-3117-0
Gu Y, Li H, Du B, Ding W (2019) Towards the understanding of creep-feed deep grinding of DD6 nickel-based single-crystal superalloy. Int J Adv Manuf Technol 100:445–455. https://doi.org/10.1007/s00170-018-2686-2
Liu Z, Li X, Wang X, Tian C, Wang L (2019) Comparative investigation on grindability of Inconel 718 made by selective laser melting (SLM) and casting. Int J Adv Manuf Technol 100:3155–3166. https://doi.org/10.1007/s00170-018-2850-8
Liu ZY, Li C, Fang XY, Guo YB (2018) Cumulative energy demand and environmental impact in sustainable machining of inconel superalloy. J Clean Prod 181:329–336. https://doi.org/10.1016/j.jclepro.2018.01.251
Ge Y, Zhu Z, Zhu Y (2019) Electrochemical deep grinding of cast nickel-base superalloys. J Manuf Process 47:291–296. https://doi.org/10.1016/j.jmapro.2019.10.007
Pratap A, Patra K, Dyakonov AA (2019) A comprehensive review of micro-grinding: emphasis on toolings, performance analysis, modeling techniques, and future research directions. Int J Adv Manuf Technol 104:63–102. https://doi.org/10.1007/s00170-019-03831-x
Huang X, Ren Y, Wu W, Li T (2019) Research on grind-hardening layer and residual stresses based on variable grinding forces. Int J Adv Manuf Technol 103:1045–1055. https://doi.org/10.1007/s00170-019-03329-6
Zhu D, Song S, Qu C, Lv Y, Wu C (2020) Numerical investigation of crack initiation, propagation and suppression in robot-assisted abrasive belt grinding of zirconia ceramics via an improved chip-thickness model. Ceram Int 46:22030–22039. https://doi.org/10.1016/j.ceramint.2020.05.199
Wang D, Sun S, Jiang J, Liu X (2019) From the grain/workpiece interaction to the coupled thermal-mechanical residual stresses: an integrated modeling for controlled stress grinding of bearing ring raceway. Int J Adv Manuf Technol 101:475–499. https://doi.org/10.1007/s00170-018-2916-7
Chen X, Öpöz TT, Oluwajobi A (2017) Analysis of grinding surface creation by single-grit approach. ASME. J Manuf Sci Eng 139(12):121007. https://doi.org/10.1115/1.4037992
Ming C, Yadong G, Yao S, Shuoshuo Q, Yin L, Yuying Y (2019) Experimental study on grinding surface properties of nickel-based single crystal superalloy DD5. Int J Adv Manuf Technol 101:71–85. https://doi.org/10.1007/s00170-018-2839-3
Dai C-W, Ding W-F, Zhu Y-J, Xu JH, Yu HW (2018) Grinding temperature and power consumption in high speed grinding of Inconel 718 nickel-based superalloy with a vitrified CBN wheel. Precis Eng 52:192–200
Zhu D, Xu X, Yang Z, Zhuang K, Yan S, Ding H (2018) Analysis and assessment of robotic belt grinding mechanisms by force modeling and force control experiments. Tribol Int 120:93–98. https://doi.org/10.1016/j.triboint.2017.12.043
Rapeti P, Pasam VK, Rao Gurram KM, Revuru RS (2018) Performance evaluation of vegetable oil based nano cutting fluids in machining using grey relational analysis-a step towards sustainable manufacturing. J Clean Prod 172:2862–2875. https://doi.org/10.1016/j.jclepro.2017.11.127
Carvalho DOA, da Silva LRR, Sopchenski L, Jackson MJ, Machado ÁR (2019) Performance evaluation of vegetable-based cutting fluids in turning of AISI 1050 steel. Int J Adv Manuf Technol 103:1603–1619. https://doi.org/10.1007/s00170-019-03636-y
Gupta MK, Song Q, Liu Z, Sarikaya M, Jamil M, Mia M, Kushvaha V, Singla AK, Li Z (2020) Ecological, economical and technological perspectives based sustainability assessment in hybrid-cooling assisted machining of Ti-6Al-4 V alloy. Sustain Mater Technol 26:e00218. https://doi.org/10.1016/j.susmat.2020.e00218
Mia M, Gupta MK, Singh G, Królczyk G, Pimenov DY (2018) An approach to cleaner production for machining hardened steel using different cooling-lubrication conditions. J Clean Prod 187:1069–1081. https://doi.org/10.1016/j.jclepro.2018.03.279
Said Z, Gupta M, Hegab H, Arora N, Khan AM, Jamil M, Bellos E (2019) A comprehensive review on minimum quantity lubrication (MQL) in machining processes using nano-cutting fluids. Int J Adv Manuf Technol 105:2057–2086. https://doi.org/10.1007/s00170-019-04382-x
Singh R, Dureja JS, Dogra M et al (2020) Evaluating the sustainability pillars of energy and environment considering carbon emissions under machining of Ti-3Al-2.5 V. Sustain Energy Technol Assessments 42:100806. https://doi.org/10.1016/j.seta.2020.100806
Maruda RW, Krolczyk GM, Feldshtein E, Pusavec F, Szydlowski M, Legutko S, Sobczak-Kupiec A (2016) A study on droplets sizes, their distribution and heat exchange for minimum quantity cooling lubrication (MQCL). Int J Mach Tools Manuf 100:81–92. https://doi.org/10.1016/j.ijmachtools.2015.10.008
Li B, Li C, Zhang Y, Wang Y, Jia D, Yang M, Zhang N, Wu Q, Han Z, Sun K (2017) Heat transfer performance of MQL grinding with different nanofluids for Ni-based alloys using vegetable oil. J Clean Prod 154:1–11. https://doi.org/10.1016/j.jclepro.2017.03.213
Khanafer K, Eltaggaz A, Deiab I, Agarwal H, Abdul-latif A (2020) Toward sustainable micro-drilling of Inconel 718 superalloy using MQL-Nanofluid. Int J Adv Manuf Technol 107:3459–3469. https://doi.org/10.1007/s00170-020-05112-4
Adibi H, Esmaeili H, Rezaei SM (2018) Study on minimum quantity lubrication (MQL) in grinding of carbon fiber-reinforced SiC matrix composites (CMCs). Int J Adv Manuf Technol 95:3753–3767. https://doi.org/10.1007/s00170-017-1464-x
Esmaeili H, Adibi H, Rezaei SM (2019) An efficient strategy for grinding carbon fiber-reinforced silicon carbide composite using minimum quantity lubricant. Ceram Int 45:10852–10864. https://doi.org/10.1016/j.ceramint.2019.02.163
Wang Y, Li C, Zhang Y, Li B, Yang M, Zhang X, Guo S, Liu G (2016) Experimental evaluation of the lubrication properties of the wheel/workpiece interface in MQL grinding with different nanofluids. Tribol Int 99:198–210
Ding Y, Shi G, Luo X, Shi G, Wang S (2020) Study on the critical negative rake angle of the negative rake angle tool based on the stagnant characteristics in micro-cutting. Int J Adv Manuf Technol 107:2055–2064. https://doi.org/10.1007/s00170-020-05158-4
Malkin S, Guo C (2008) Grinding technology: theory and application of machining with abrasives. Industrial Press, New York
Merchant ME (1945) Mechanics of the metal cutting process. II Plasticity conditions in orthogonal cutting. J Appl Phys 16:318–324
Ozturk S, Altan E (2013) Position of the separation point in machining with a rounded-edge tool. Proc Inst Mech Eng Part B J Eng Manuf 227:965–971. https://doi.org/10.1177/0954405413484137
Malekian M, Mostofa MG, Park SS, Jun MBG (2012) Modeling of minimum uncut chip thickness in micro machining of aluminum. J Mater Process Technol 212:553–559
Timoshenko SP, Goodier JN (1970) Theory of elasticity 3rd edn. McGraw-Hill, New York
Iturbe A, Giraud E, Hormaetxe E, Garay A, Germain G, Ostolaza K, Arrazola PJ (2017) Mechanical characterization and modelling of Inconel 718 material behavior for machining process assessment. Mater Sci Eng A 682:441–453. https://doi.org/10.1016/j.msea.2016.11.054
Long Y, Guo C, Ranganath S, Talarico RA (2010) Multi-phase FE model for machining Inconel 718. In: Proceedings of the ASME 2010 International Manufacturing Science and Engineering Conference, Volume 1. Erie, Pennsylvania, USA. October 12–15, 2010. pp 263–269. ASME. https://doi.org/10.1115/MSEC2010-34233
Shi Y, Wang Z, Xu S, Yu T, Sun Z (2019) Study on the grindability of nano-vitrified bond CBN grinding wheel for nickel-based alloy. Int J Adv Manuf Technol 100:1913–1921. https://doi.org/10.1007/s00170-018-2807-y
Wang J, Yu T, Ding W, Fu Y, Bastawros AF (2018) Wear evolution and stress distribution of single CBN superabrasive grain in high-speed grinding. Precis Eng 54:70–80
Xie W, Yang F, Ding L, Scarpa F (2019) Predictive models and experiments for high-velocity and high-temperature impacts in Inconel-alloy panels. Mater Des 182:108032
Liu C, Ding W, Yu T, Yang C (2018) Materials removal mechanism in high-speed grinding of particulate reinforced titanium matrix composites. Precis Eng 51:68–77. https://doi.org/10.1016/j.precisioneng.2017.07.012
Hao Z, Ji F, Fan Y, Zhang N (2019) Failure feature and characterization of material of shear band in cutting Inconel718. J Manuf Process 45:154–165. https://doi.org/10.1016/j.jmapro.2019.06.016
Shi G, Deng X, Shet C (2002) A finite element study of the effect of friction in orthogonal metal cutting. Finite Elem Anal Des 38:863–883. https://doi.org/10.1016/s0168-874x(01)00110-x
Özel T, Altan T (2000) Determination of workpiece flow stress and friction at the chip–tool contact for high-speed cutting. Int J Mach Tools Manuf 40:133–152. https://doi.org/10.1016/S0890-6955(99)00051-6
Dib MHM, Duduch JG, Jasinevicius RG (2018) Minimum chip thickness determination by means of cutting force signal in micro endmilling. Precis Eng 51:244–262. https://doi.org/10.1016/j.precisioneng.2017.08.016
Son SM, Lim HS, Ahn JH (2005) Effects of the friction coefficient on the minimum cutting thickness in micro cutting. Int J Mach Tools Manuf 45:529–535
Bissacco G, Hansen HN, Slunsky J (2008) Modelling the cutting edge radius size effect for force prediction in micro milling. CIRP Ann 57:113–116
Derringer G, Suich R (1980) Simultaneous optimization of several response variables. J Qual Technol 12:214–219. https://doi.org/10.1080/00224065.1980.11980968
Li B, Li C, Zhang Y, Wang Y, Jia D, Yang M (2016) Grinding temperature and energy ratio coefficient in MQL grinding of high-temperature nickel-base alloy by using different vegetable oils as base oil. Chinese J Aeronaut 29:1084–1095. https://doi.org/10.1016/j.cja.2015.10.012
Chen J, Fang Q, Zhang L (2014) Investigate on distribution and scatter of surface residual stress in ultra-high speed grinding. Int J Adv Manuf Technol 75:615–627
Pavan RB, Venu Gopal A, Amrita M, Goriparthi BK (2019) Experimental investigation of graphene nanoplatelets–based minimum quantity lubrication in grinding Inconel 718. Proc Inst Mech Eng Part B J Eng Manuf 233:400–410
Singh R, Dureja JS, Dogra M, Gupta MK, Mia M (2019) Influence of graphene-enriched nanofluids and textured tool on machining behavior of Ti-6Al-4V alloy. Int J Adv Manuf Technol 105:1685–1697
Zhang X, Li C, Zhang Y, Wang Y, Li B, Yang M, Guo S, Liu G, Zhang N (2017) Lubricating property of MQL grinding of Al2O3/SiC mixed nanofluid with different particle sizes and microtopography analysis by cross-correlation. Precis Eng 47:532–545. https://doi.org/10.1016/j.precisioneng.2016.09.016
Zhang D, Li C, Jia D, Zhang Y, Zhang X (2015) Specific grinding energy and surface roughness of nanoparticle jet minimum quantity lubrication in grinding. Chinese J Aeronaut 28:570–581
Availability of data and material
Not applicable.
Author information
Authors and Affiliations
Contributions
Hamed Esmaeili: investigation, performing theoretical analysis, performing numerical simulations, developing statistical model and optimization, carrying out experiments, writing paper. Hamed Adibi: supervision, investigation, providing resources and equipment, project administration. Seyed Mehdi Rezaei: supervision, investigation, providing resources and equipment, project administration. All authors discussed the results and contributed to the final manuscript.
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no competing interests.
Code availability
Not applicable.
Ethics approval
Not applicable.
Consent to participate
Not applicable.
Consent for publication
Not applicable.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Esmaeili, H., Adibi, H. & Rezaei, S.M. Study on surface integrity and material removal mechanism in eco-friendly grinding of Inconel 718 using numerical and experimental investigations. Int J Adv Manuf Technol 112, 1797–1818 (2021). https://doi.org/10.1007/s00170-020-06528-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-020-06528-8