Journal Article

Parametric optimization and process capability analysis for machining of nickel-based superalloy

Mikolajczyk, Tadeusz, Sharma, Vishal S., Nadolny, Krzysztof, Pruncu, Catalin I., Pimenov, Daniil Yu, Mia, Mozammel, Kapłonek, Wojciech, Sarikaya, Murat, Gupta, Munish Kumar, Patra, Karali

2019

Overview

The manufacturing of parts from nickel-based superalloy, such as Inconel-800 alloy, represents a challenging task for industrial sites. Their performances can be enhanced by using a smart cutting fluid approach considered a sustainable alternative. Further, to innovate the cooling strategy, the researchers proposed an improved strategy based on the minimum quantity lubrication (MQL). It has an advantage over flood cooling because it allows better control of its parameters (i.e., compressed air, cutting fluid). In this study, the machinability of superalloy Inconel-800 has been investigated by performing different turning tests under MQL conditions, where no previous data are available. To reduce the numerous numbers of tests, a target objective was applied. This was used in combination with the response surface methodology (RSM) while assuming the cutting force input ( F c ), potential of tool wear (VB max ), surface roughness ( R a ), and the length of tool–chip contact ( L ) as responses. Thereafter, the analysis of variance (ANOVA) strategy was embedded to detect the significance of the proposed model and to understand the influence of each process parameter. To optimize other input parameters (i.e., cutting speed of machining, feed rate, and the side cutting edge angle (cutting tool angle)), two advanced optimization algorithms were introduced (i.e., particle swarm optimization (PSO) along with the teaching learning-based optimization (TLBO) approach). Both algorithms proved to be highly effective for predicting the machining responses, with the PSO being concluded as the best amongst the two. Also, a comparison amongst the cooling methods was made, and MQL was found to be a better cooling technique when compared to the dry and the flood cooling.

• Publisher: Springer London,Springer Nature B.V
• Subject: Algorithms / CAE) and Design / Compressed air / Computer-Aided Engineering (CAD / Cooling / Cutting fluids / Cutting force / Cutting parameters / Cutting speed / Cutting tools / Cutting wear / Engineering / Feed rate / Flood control / Industrial and Production Engineering / Lubrication / Machinability / Machine learning / Mechanical Engineering / Media Management / Nickel / Nickel base alloys / Optimization / Original Article / Particle swarm optimization / Performance enhancement / Process capability analysis / Process parameters / Response surface methodology / Strategy / Superalloys / Surface roughness / Tool wear / Turning (machining) / Variance analysis