Experimental Evaluation of Machinability of Monel 400 Alloy During High Speed Micro Milling Using Various Tool Coatings

• Autorzy: Baig Amjad , Khan Muhammad Ali , Jaffery Syed Husain Imran , Khan Mushtaq , Naseer Rashid , Shah Imran , Petru Jana

Identyfikatory

DOI

10.12913/22998624/190624

• Języki publikacji: EN

Abstrakty

EN

Quality of finished miniature products is characterized by surface roughness as well as burr formation after manufacturing processes. It gains more significance when it is gauged in terms of high precision and dimensional accuracy of final micro parts. The requirement of complex fea-tures in 3D micro parts also figures out its significance. Similarly, tool wear is an important indicator of production efficiency and quality related to finished parts. In the current research, the impact of key input parameters like depth of cut, feed rate, cutting speed and various tool coatings (TiAlN, TiSiN, nACo, including an uncoated tool) were statistically analyzed while carrying out micro-milling of Monel 400 super alloy. Sur-face roughness along with burr formation and tool wear were considered as response parameters due to their significant nature. Machining ex-periments were performed up to 80,000 rpm (high-speed range). Feed rate values were selected in comparison with cutting tool edge radius. The selected values of feed rate were taken into consideration at moderate and high-speed ranges while selecting the values equal to below and above the values of cutting-edge radius. Digital microscopy and scanning electron microscope (SEM) were utilized for analysis in addition to statistical techniques for response parameters. Methodology utilizes Taguchi's Experimental design. L16 orthogonal array was formulated to carry out mi-cro milling experiments on Monel 400 specimen, having dimensions 20mm x 30mm x 40mm. Contribution ratio (CR) of individual input pa-rameter was calculated through Analysis of Variance (ANOVA). The outcome of experimental work indicated that feed rate was the most sig-nificant factor for surface roughness with CR 27.86%. It also became most significant factor for top burr width in both categories (Up-milling & down-milling) with CR 56.56% and 56.60% respectively. Moreover, it was also most significant factor for top burr height in both categories (Up-milling & down-milling) with CR 23.84% and CR 28.47% respectively. Whereas in case of tool wear, the depth of cut and tool coatings were significant factors with CR 19.46% and 28.47% respectively.

Słowa kluczowe

EN

micromilling; Monel 400 alloy; manufacturing processes; Taguchi design of experiments; process design; sustainability; green manufacturing; precision machining

• Wydawca: Lublin University of Technology ; Polish Society of Ecological Engineering (PTIE), Branch of PTIE in Lublin
• Czasopismo: Advances in Science and Technology. Research Journal
• Rocznik: 2024
• Tom: Vol. 18, no. 5
• Strony: 298--317
• Opis fizyczny: Bibliogr. 52 poz., fig., tab.

Twórcy

autor

Baig Amjad

• School of Mechanical and Manufacturing Engineering (SMME), National University of Sciences and Technology (NUST), Islamabad 44000, Pakistan

autor

Khan Muhammad Ali

• School of Mechanical and Manufacturing Engineering (SMME), National University of Sciences and Technology (NUST), Islamabad 44000, Pakistan

• https://orcid.org/0000-0003-0716-2304

autor

Jaffery Syed Husain Imran

• School of Mechanical and Manufacturing Engineering (SMME), National University of Sciences and Technology (NUST), Islamabad 44000, Pakistan

autor

Khan Mushtaq

• Mechanical Engineering Department, Prince Mohammad Bin Fahd University, AL-Khobar 31952, Saudi Arabia

autor

Naseer Rashid

• Department of Mechanical Engineering, College of Electrical and Mechanical Engineering (CEME), National University of Sciences and Technology (NUST), Islamabad 44000, Pakistan

autor

Shah Imran

• Department of Mechatronics Engineering, Air University, Islamabad 44000, Pakistan

autor

Petru Jana

• Department of Machining, Assembly and Engineering Metrology, Mechanical Engineering Faculty, VŠB-Technical University of Ostrava, 17, Listopadu 2172/15, 708 00 Ostrava, Czech Republic

Bibliografia

• 1. Jaffery S.H.I., Khan M.L. Ali, Mativenga P.T. Statistical analysis of process parameters in micromachining of Ti-6Al-4V alloy, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., Jun. 2016; 230(6): 1017–1034.
• 2. Khan M.A. et al. Experimental evaluation of Surface roughness, burr formation, and tool wear during micro-milling of Titanium Grade 9 (Ti-3Al-2.5V) Using Statistical Evaluation Methods, Appl. Sci., 2023; 13(23), doi: 10.3390/app132312875
• 3. Sheheryar M. et al. Multi-objective optimization of process parameters during micro-milling of nickel- based alloy Inconel 718 using Taguchi-Grey relations integrated approach. Mater. 2022; 15(23): 8296, doi: 10.3390/MA15238296.
• 4. Corbett J., McKeown R.A., Peggs G.N., Whatmore R. Nanotechnology: International developments and emerging products. CIRP Ann. - Manuf. Technol., 2000; 49(2): 523–545.
• 5. Weng F., Liu Y., Chew Y., Yao X., Sui S., Tan C., Ng F.L., Bi G. IN100 Ni-based superalloy fabricated by micro-laser aided additive manufacturing: Correlation of the microstructure and fracture mechanism. Materials Sci. Eng. A, 2020. doi: 10.1016/j. msea.2020.139467.
• 6. Younas M. et al. Multi-objective optimization for sustainable turning Ti6Al4V alloy using grey relational analysis (GRA) based on analytic hierarchy process (AHP). Int. J. Adv. Manuf. Technol., Nov. 2019; 105(1–4): 1175–1188.
• 7. Khan M.A. et al. Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions. Mech. Sci., 2019; 10(2): 561–573.
• 8. Jin, Xiaoliang, Yusuf Altintas. Prediction of micromilling forces with finite element method. Journal of Materials Processing Technology 2012; 212(3): 542–552.
• 9. Wang, Fei, Xiang Cheng, Yuanyong Liu, Xianhai Yang, and Fanjie Meng. Micromilling simulation for the hard-to-cut material. Procedia Engineering 2017;174: 693–699.
• 10. Khan M.A., Jaffery S.H.I., Khan M., Alruqi M. Machinability analysis of Ti-6Al-4V under cryogenic condition. Journal of Materials Research and Technology 2023; 25: 2204–2226.
• 11. Khan M.A., Jaffery S.H.I., aKhan M. Assessment of sustainability of machining Ti-6Al-4V under cryogenic condition using energy map approach, Eng. Sci. Technol. an Int. J., May 2023; 41: 101357.
• 12. Yang Y., Han J., Hao X., Li L., He N. Investigation on micro-milling of micro-grooves with high aspect ratio and laser deburring, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., Apr. 2020; 234(5): 871–880. doi: 10.1177/0954405419893491.
• 13. Ahmad A., Khan M.A., Akram S., Faraz M.I., Jaffery S.H.I., Iqbal T., Petru J. Achieving sustainable machining of titanium grade 3 alloy through optimization using grey relational analysis (GRA). Results in Engineering 2024; 102355.
• 14. Baig A., Jaffery S.H.I., Khan M.A., Alruqi M. Statistical analysis of surface roughness, burr formation and tool wear in high speed micro milling of inconel 600 alloy under cryogenic, wet and dry conditions. Micromachines 2022; 14(1): 13.
• 15. El-Baradie M. Machinabililty of nickel-base super alloys: a general review. Journal of Materials Processing Technology(Netherlands) 1995, 77(1): 278–284.
• 16. Davami M. and Zadshakoyan M. Investigation of tool temperature and surface quality in hot machining of hard-to-cut materials. International Journal of Materials and Metallurgical Engineering 2008; 2(10): 252–256.
• 17. Ezugwu, E.O. Key improvements in the machining of difficult-to-cut aerospace superalloys. International Journal of Machine Tools and Manufacture 2005; 45, 12–13: 1353–1367.
• 18. Abd Rahman M., Ali M.Y., Khairuddin A.S. Effects on vibration and surface roughness in high speed micro end-milling of inconel 718 with minimum quantity lubrication. In: IOP Conference Series, Materials Science and Engineering, 184(1), 012037. IOP Publishing, 2017.
• 19. Azhdari Tadavani S., Shoja Razavi R., and Vafaei R. Pulsed laser-assisted machining of Inconel 718 superalloy, Opt. Laser Technol., 2017; 87: 72–78.
• 20. Siddique M.Z., Faraz M.I., Butt S.I., Khan R., Petru J., Jaffery S.H.I, Khan M.A., Tahir A.M. Parametric analysis of tool wear, surface roughness and energy consumption during turning of Inconel 718 under dry, wet and MQL conditions. Machines 2023; 11(11):1008. https://doi.org/10.3390/ machines11111008
• 21. Ucun I., Aslantas K., Bedir F., An experimental investigation of the effect of coating material on tool wear in micro milling of Inconel 718 super alloy, Wear, 2013; 300(1–2): 8–19.
• 22. Aslantas K., Hopa H.E., Percin M., Ucun I., Çicek A. Cutting performance of nano-crystalline diamond (NCD) coating in micro-milling of Ti6Al4V alloy, Precis. Eng., 2016; 45: 55–66, doi: 10.1016/j. precisioneng.2016.01.009.
• 23. Özel T., Thepsonthi T., Ulutan D., Kaftanolu B. Experiments and finite element simulations on micro-milling of Ti-6Al-4V alloy with uncoated and cBN coated micro-tools, CIRP Ann. - Manuf. Technol., 2011; 60(1): 85–88.
• 24. Aramcharoen A., Mativenga P.T., Yang S., Cooke K.E., and Teer D.G. Evaluation and selection of hard coatings for micro milling of hardened tool steel, Int. J. Mach. Tools Manuf., 2008; 48(14): 1578–1584.
• 25. Imran, M., Mativenga, P.T., Gholinia, A., Withers, P.J. Comparison of tool wear mechanisms and surface integrity for dry and wet micro-drilling of nickel-base superalloys. International Journal of Machine Tools and Manufacture 2014; 76, 49–60.
• 26. Khan M.A, Jaffery S.H.I, Khan M.A, Faraz M.I, Mufti S. Multi-objective optimization of micro-milling titanium alloy Ti-3Al-2.5V (grade 9) using taguchi-grey relation integrated approach. Metals. 2023; 13(8):1373. https://doi.org/10.3390/met13081373
• 27. Zaidi S.R., Ul Qadir N., Jaffery S.H.I., Khan M.A., Khan M., Petru J. Statistical analysis of machining parameters on burr formation, surface roughness and energy consumption during milling of aluminium alloy Al 6061-T6. Materials. 2022; 15(22): 8065. https://doi.org/10.3390/ma15228065
• 28. Dornfeld D., Min S., Takeuchi Y.. 2006. Recent advances in mechanical micromachining. CIRPAnnals, 55(2), 745-768. Available: https://www.sciencedi- rect.com/science/article/pii/S1660277306000077
• 29. Petru, J. Experimental investigation of cutting forces in high-feed milling of titanium alloy. Advances in Science and Technology. Research Journal, 2020; 14(1): 89–95.
• 30. Khan M.A. et al. Multi-objective optimization of turning titanium-based alloy Ti-6Al-4V under dry, wet, and cryogenic conditions using gray relational analysis (GRA), Int. J. Adv. Manuf. Technol., 2020; 106(9–10): 3897–3911, doi: 10.1007/ s00170-019-04913-6.
• 31. Tansel I.N. et al. Tool wear estimation in micro-machining.: Part I: Tool usage–cutting force relation- ship, Elsevier, 2000; 40, Accessed: Sep. 15, 2023. [Online]. Available: https://www.sciencedirect. com/science/article/pii/S0890695599000735
• 32. Weule, H., V. Hüntrup, H. Tritschler. Micro-cutting of steel to meet new requirements in miniaturization. CIRP Annals 2001; 50(1): 61–64.
• 33. Zhang P. Investigation on the mechanism of micromilling CoCrFeNiAlX high entropy alloys with end milling cutters. Vacuum, 2023, 211, 111939. https://www.sciencedirect.com/science/article/pii/ S0042207X23001367
• 34. Rauf, Adil, Muhammad Ali Khan, Syed Husain Imran Jaffery, and Shahid Ikramullah Butt. Effects of machining parameters, ultrasonic vibrations and cooling conditions on cutting forces and tool wear in meso scale ultrasonic vibrations assisted end-milling (UVAEM) of Ti-6Al-4V under dry, flooded, MQL and cryogenic environments – a statistical analysis. Journal of Materials Research and Technology 2024.
• 35. Attanasio A., Gelfi M., Pola A., Ceretti E., Giardini C. Influence of material microstructures in micro-milling of Ti6Al4V alloy. Materials 2023, 6(9): 4268–4283.
• 36. Aurich J.C., Bohley M., Reichenbach I.G., Kirsch B. Surface quality in micro milling: Influences of spindle and cutting parameters, CIRP Ann. - Manuf. Technol., 2017; 66(1): 101–104.
• 37. Bai, Jinxuan, Qingshun Bai, and Zhen Tong. Mul- tiscale analyses of surface failure mechanism of single-crystal silicon during micro-milling process. Materials 2017; 10(12): 1424.
• 38. Khan, Muhammad Ali, Syed Husain Imran Jaffery, Aamer Ahmed Baqai, and Mushtaq Khan. Comparative analysis of tool wear progression of dry and cryogenic turning of titanium alloy Ti-6Al-4V under low, moderate and high tool wear conditions. The International Journal of Advanced Manufacturing Technology 2022; 121(1): 1269–1287.
• 39. Ahmad, Adnan, Sohail Akram, Syed Husain Imran Jaffery, and Muhammad Ali Khan. Evaluation of specific cutting energy, tool wear, and surface roughness in dry turning of titanium grade 3 alloy. The International Journal of Advanced Manufacturing Technology 2023; 127(3): 1263–1274.
• 40. Taguchi, G. and Yokoyama Y. Taguchi methods: design of experiments. 1993; 4. Amer Supplier Inst.
• 41. Khan, Muhammad Ali, Syed Husain Imran Jaffery,Mushtaq Khan, Shahid Ikramullah Butt. Wear and surface roughness analysis of machining of Ti-6Al- 4V under dry, wet and cryogenic conditions. In: IOP Conference Series: Materials Science and Engineer
• 42. Khan, Zarak, Mushtaq Khan, Syed Husain Imran Jaffery, Muhammad Younas, Kamran S. Afaq, Muhammad Ali Khan. Numerical and experimental investigation of the effect of process parameters on sheet deformation during the electromagnetic forming of AA6061-T6 alloy. Mechanical Sciences 2020; 11(2): 329–347.
• 43. Bajpai, V., Kushwaha A.K., Singh R.K. Burr formation and surface quality in high speed micromilling of titanium alloy (Ti6Al4V). In International Manufacturing Science and Engineering Conference. 2013. American Society of Mechanical Engineers.
• 44. Kim, D.H., Lee P.-H., Lee S.W. Experimental study on machinability of Ti-6Al-4V in micro end-milling. in Proceedings of the World Congress on Engineering. 2014.
• 45. Jaffery, S. and Mativenga P. Assessment of the machinability of Ti-6Al-4V alloy using the wear map approach. The International Journal of Advanced Manufacturing Technology, 2009; 40(7): 687–696.
• 46. Mian, A.J., Driver N., Mativenga P.T. A comparative study of material phase effects on micro-machinability of multiphase materials. The International Journal of Advanced Manufacturing Technology, 2010; 50(1): 163–174.
• 47. Filiz, S., et al. An experimental investigation of micromachinability of copper 101 using tungsten carbide micro-endmills. International Journal of Machine Tools and Manufacture, 2007; 47(7–8): 1088–1100.
• 48. Lee, K., An experimental study on burr formation in micro-milling aluminium and copper. Trans NAMRI/SME, 2002.
• 49. Aramcharoen, A. and Mativenga P. Size effect and tool geometry in micromilling of tool steel. Precision Engineering, 2009; 33(4): 402–407.
• 50. Park, J., et al. Evaluation of machinability in the micro end milling of printed circuit boards. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2009; 223(11): 1465–1474.
• 51. Mian, A., Driver N., and Mativenga P. Identification of factors that dominate size effect in micromachining. International Journal of Machine Tools and Manufacture, 2011; 51(5): 383–394.
• 52. Ahsan, K.B. et al. Study on carbide cutting tool life using various cutting speeds for α-β Ti-alloy machining. Journal of Achievements in Materials and Manufacturing Engineering, 2012; 55(2): 601–606.ing, 689(1), 012006. IOP Publishing, 2019.