Article
Chemistry, Physical
Agata Felusiak-Czyryca, Marek Madajewski, Pawel Twardowski, Martyna Wiciak-Pikula
Summary: Inconel 718 alloy is commonly used in aerospace and marine industries due to its properties, but its difficult machinability poses challenges. Turn-milling is a method that can alleviate the difficulty, but tool wear remains a concern due to increased forces during machining.
Review
Materials Science, Multidisciplinary
Ghulam Mustafa, Muhammad Tuoqeer Anwar, Arslan Ahmed, Muhammad Nawaz, Tahir Rasheed
Summary: Inconel 718, a nickel-based superalloy, is well-known for its excellent physical and mechanical properties at high temperatures. However, its high strength and hardness lead to poor machinability. Many studies have been conducted to understand and optimize the machining of Inconel 718, with a focus on cutting parameters and machinability features such as cutting tool wear, cutting forces, and surface reliability.
ADVANCED ENGINEERING MATERIALS
(2022)
Article
Automation & Control Systems
Paolo Parenti, Francesco Puglielli, Massimo Goletti, Massimiliano Annoni, Michele Monno
Summary: Solid ceramic end mills can achieve higher material removal rates for machining heat resistant super alloys, but may have limited tool life and potential heat-related issues. Study showed cutting strategy and speed significantly affect cutting signals and workpiece integrity.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Moran Xu, Shuo Chen, Rendi Kurniawan, Changping Li, Rong Wei, Hanwei Teng, Thirumalai Kumaran, Pil Wan Han, Tae Jo Ko
Summary: A new machining method, cryogenic-ultrasonic vibration-assisted milling (CUVAM), was proposed to improve the workability of Inconel 718. The study compared the effects of conventional machining (CM), cryogenic cooling machining (CCM), and CUVAM on cutting force, chip, tool life, workpiece surface morphology, and surface integrity. The results showed that cryogenic assistance could improve the machining environment and coefficient of friction, while ultrasonic vibration assistance in CUVAM suppressed the increase in cutting force. Compared to CM, CUVAM reduced cutting force by 36.5% and had a beneficial impact on tool life. The surface roughness after CUVAM was also significantly reduced compared to CCM.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Review
Engineering, Industrial
Andrea De Bartolomeis, Stephen T. Newman, I. S. Jawahir, Dirk Biermann, Alborz Shokrani
Summary: Inconel 718 is a popular nickel-based superalloy extensively used in aerospace, automotive, and energy industries. However, machining of Inconel 718 remains challenging due to its short tool life and low productivity. Recent advances in cutting tool materials, coatings, geometries, and surface texturing for machining Inconel 718 have been reviewed, with a focus on the thermal conductivity of cutting tool materials. Process control based on sensor data for monitoring machining and detecting anomalies has been identified as crucial for machining safety critical components.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Dongdong Xu, Yang Liu, Liang Ding, Jinming Zhou, Rachid M'Saoubi, Haijiang Liu
Summary: This study investigates the cutting process of nickel-based superalloy Inconel 718 with worn tools using both numerical and experimental methods. The results show that worn tools have an influence on thermal distribution, force variation, and tool wear performance. A white layer appears on the subsurface due to intense friction and significant heat generation caused by tool wear, altering the stress condition and thermal distribution. EBSD and SEM results demonstrate variations in subsurface material and deformation under different cutting conditions. The findings from both numerical and experimental methods are consistent, highlighting the ability to study cutting performance with worn tools numerically and reducing resource requirements for studying surface deformation.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Automation & Control Systems
Amaia Jimenez, Miguel Arizmendi, Jose Manuel Sanchez
Summary: The paper introduces an experimental method for predicting tool wear in drilling Inconel 718 superalloy by analyzing drilling force signals and tool wear progress. The study shows that mean value of thrust force and standard deviation of high frequency components are the most sensitive indicators for drill wear.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Chemistry, Multidisciplinary
Tian-Yau Wu, Chi-Chen Lin
Summary: This research aims to investigate the feasibility of using the Elman neural network to predict the surface roughness in the milling process of Inconel 718 and optimizing the cutting parameters through the PSO algorithm. The experimental results demonstrate the accurate prediction of surface roughness and determination of the optimal cutting parameter combination.
APPLIED SCIENCES-BASEL
(2021)
Article
Engineering, Manufacturing
Ganesh S. Kadam, Raju S. Pawade
Summary: High-speed turning of Inconel 718 was conducted using coated carbide tooling and minutely explored eco-friendly cutting fluid, water vapour. The effects of seven parameters including nozzle diameter, stand-off distance, pressure, flowrate, cutting speed, feedrate, and depth of cut on surface roughness and surface alterations were investigated. The cooling/lubrication mechanics of water vapour at the tool-work interface were evaluated through chip reduction ratio analysis. The parameters of stand-off distance, cutting speed, feedrate, and depth of cut had significant effects on surface roughness, with contributions of 9.70%, 22.70%, 20.85%, and 34.47% respectively. Increasing nozzle diameter, stand-off distance, and pressure led to reductions in surface roughness by approximately 13.28%, 16.47%, and 8.82% respectively, due to enhanced cooling and lubrication effects. However, increasing cutting speed resulted in a 40% increase in surface roughness.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Engineering, Manufacturing
M. Karthick, P. Anand, M. Siva Kumar, M. Meikandan
Summary: This study optimized the parameters of plasma arc cutting of Inconel 718 superalloy sheet through response surface analysis, finding that the MFO algorithm was feasible in predicting and optimizing the PAC process to achieve the optimal processing conditions.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Mechanical
Jean-Briac le Graverend
Summary: A phenomenological model is proposed to predict both monotonic and cyclic softening in Inconel 718 superalloy at 650℃. Crystal-plasticity finite-element simulations are performed to validate the model and gain insights on the ratcheting phenomenon.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Engineering, Multidisciplinary
Cristian Fabian Perez-Salinas, Pablo Fernandez-Lucio, Ander del Olmo, Inigo Aldekoa-Gallarza, Luis Norberto Lopez de Lacalle
Summary: This study aims to investigate the influence of brushing the cutting edge on cutting force, energy consumption, tool wear, and cutting edge temperature during the production of turbine disc dovetails. The results show that increasing the cutting edge radius significantly affects the cutting force and surface quality. Through experimental tests and simulations, it was found that a 12 μm cutting edge radius exhibits the best performance.
ENGINEERING SCIENCE AND TECHNOLOGY-AN INTERNATIONAL JOURNAL-JESTECH
(2023)
Article
Automation & Control Systems
Huseyin Gurbuz, Sehmus Baday
Summary: Inconel 718 is a material with low machinability due to high cutting temperatures, BUE, cutting forces, and work hardening during machining. Cryogenic process has been applied to increase wear resistance and hardness of cutting tools. Experiment results showed that cryogenically treated cutting tools reduced feed forces, surface roughness, vibration, and cutting tool wear, while increasing feed rate and cutting speed led to higher surface roughness, vibration, and feed force values. Vibration was found to be significantly related to surface roughness, and an inverse relationship was observed between abrasive wear and hardness values.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Optics
Tarlochan Singh, Julfekar Arab, Shih-Chi Chen
Summary: This paper presents a combined gas-assisted laser machining and wire electrochemical machining (W-ECM) process for improving the surface quality of slits produced in Inconel-718, a widely used high-strength nickel-based alloy in aircraft engine parts. Laser cutting was first applied to produce the slit structure and optimize the processing parameters, followed by the custom-developed W-ECM process. The combined approach achieved a 90% average improvement in surface finish with a 10% increase in kerf width, eliminating striation marks and thermal damages.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Amin Bagherzadeh, Erhan Budak, Emre Ozlu, Bahattin Koc
Summary: The combination of additive and machining processes can achieve sustainable and cleaner production by using eco-friendly materials, reducing waste and energy consumption, and ensuring precision and product quality. However, there is a lack of research on material deformation and friction behavior in hybrid additive/subtractive manufacturing, which is necessary for optimizing process efficiency and achieving cleaner production.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2023)
Article
Computer Science, Artificial Intelligence
Longhua Xu, Chuanzhen Huang, Chengwu Li, Jun Wang, Hanlian Liu, Xiaodan Wang
Summary: In this study, an improved case based reasoning method (ICBR) was proposed to predict surface roughness and residual stress in high-speed milling process. ICBR, which combines K-nearest neighbor method and artificial neural network, provides accurate estimation of surface quality under different tool wear status and cutting parameters. Experimental results showed that cutting speed is the most important factor affecting surface roughness, while the most influential factor on residual stress is the feed rate.
JOURNAL OF INTELLIGENT MANUFACTURING
(2021)
Article
Computer Science, Artificial Intelligence
Longhua Xu, Chuanzhen Huang, Chengwu Li, Jun Wang, Hanlian Liu, Xiaodan Wang
Summary: The study proposed an intelligent model, ANFIS, to estimate tool wear, which showed better performance compared with other intelligent models. Additionally, the VCPSO algorithm was used to obtain the best combinations of milling parameters based on minimum cutting power, surface roughness, and maximum MRR.
JOURNAL OF INTELLIGENT MANUFACTURING
(2021)
Article
Engineering, Manufacturing
Longhua Xu, Chuanzhen Huang, Chengwu Li, Jun Wang, Hanlian Liu, Xiaodan Wang
Summary: In the process of intelligent manufacturing, the use of suitable learning algorithms and intelligent models is essential. This study proposes a novel learning algorithm called random vibration and cross particle swarm optimization algorithm for prediction and optimization of machining process. The algorithm is able to find the global optimum and provide accurate predictions for tool wear width size. The optimized cutting parameters can prolong tool life and improve machining efficiency.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2022)
Article
Computer Science, Artificial Intelligence
Yun Chen, Huaizhong Li, Liang Hou, Xiangjian Bu, Shaogan Ye, Ding Chen
Summary: This paper investigates the use of a novel p-leader multifractal formalism for chatter detection in milling processes. The proposed method can accurately detect chatter without prior knowledge of the machining system's natural frequencies. Experimental studies and numerical simulations were conducted to verify the effectiveness of the method. The results show that the proposed method outperforms the commonly-used methods in terms of classification accuracies, especially for unstable tests.
JOURNAL OF INTELLIGENT MANUFACTURING
(2022)
Article
Automation & Control Systems
Hao Yun, Bin Zou, Jun Wang, Chuanzhen Huang, Zhenyu Shi
Summary: The optimal cutting speeds for coated cemented carbide and welding PCBN tools are 55 m/min and 92 m/min, respectively, with an increase in cutting speed leading to corresponding changes in material removal volume.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Electrical & Electronic
Ru Zhang, Chuanzhen Huang, Jun Wang, Shaochuan Feng, Hongtao Zhu
Summary: An experimental study was conducted to investigate the evolution from micro/nano-structural arrays to V-grooves under femtosecond laser irradiations. It was found that increasing laser fluence, scan speed, or the number of scans gradually leads to this evolution, with various underlying mechanisms such as laser-induced surface instability, hatching effects, Coulomb explosions, melting, and evaporation. The study also showed that laser-induced surface changes and nanoparticle agglomeration were influenced by laser fluence, affecting the boundary between different surface structures.
MATERIALS SCIENCE IN SEMICONDUCTOR PROCESSING
(2021)
Article
Materials Science, Ceramics
Dun Liu, Chuanzhen Huang, Jun Wang, Hongtao Zhu
Summary: The study established a prediction model for depth of penetration after AWJ turning of alumina ceramic and analyzed the material removal mechanism. The predicted model showed good results and indicated a mixed removal mechanism of brittle fracture and plastic shear for alumina ceramics turned by AWJ.
CERAMICS INTERNATIONAL
(2021)
Article
Materials Science, Ceramics
Ru Zhang, Chuanzhen Huang, Jun Wang, Dongkai Chu, Dun Liu, Shaochuan Feng
Summary: In this study, response surface methodology was used to accurately predict the groove depth, width, heat affected zone (HAZ), and material removal rate (MRR) in SiC femtosecond laser processing. The study found that laser fluence, scan speed, repetition rate, and multipass scanning significantly influenced the processing parameters.
CERAMICS INTERNATIONAL
(2022)
Article
Engineering, Manufacturing
Xiubing Jing, Zehui Zheng, Jian Xu, Fujun Wang, Syed Husain Imran Jaffery, Huaizhong Li
Summary: The aim of this research is to analyze the stability of micro milling process using the p-leader multifractal method. Two indicators are designed based on the p-leader multifractal spectrum to identify the stable, weak-chatter, and chatter occurrence. The analysis of experimental data and numerical simulation verifies the effectiveness of the p-leader multifractal method and the proposed indicators.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Electrical & Electronic
Pablo Guzman, Toan Dinh, Afzaal Qamar, Jaesung Lee, X. Q. Zheng, Philip Feng, Mina Rais-Zadeh, Hoang-Phuong Phan, Thanh Nguyen, Abu Riduan Md Foisal, Huaizhong Li, Nam-Trung Nguyen, Dzung Viet Dao
Summary: This paper introduces a new concept of bi-layered monolithic silicon carbide resonators that utilize thermal-piezoresistive pumping to boost the quality factor. The device operates through electrothermal actuation and the structural stress modulates the electrothermal force via the piezoresistive effect. The unique design of the double SiC layer allows energy to be pumped into the system, resulting in an enhancement of the effective quality factor.
SENSORS AND ACTUATORS A-PHYSICAL
(2022)
Article
Engineering, Multidisciplinary
Vigneshwar Kannan, Dzung Viet Dao, Huaizhong Li
Summary: In machinery condition monitoring, considering information from multiple sources is important to avoid misclassification caused by sensor failure or signal distortion. This paper proposes a novel method for information fusion that increases the reliability of machinery health diagnosis by training classifiers and utilizing signal integrity features.
STRUCTURAL HEALTH MONITORING-AN INTERNATIONAL JOURNAL
(2023)
Article
Mechanics
Yiwen Gu, Thai Nguyen, Matthew J. Donough, B. Gangadhara Prusty, Jun Wang
Summary: This paper investigates the formation mechanism of delamination in entrainment abrasive waterjet machines and finds that the delamination phenomenon is mainly caused by the material's response to shock pressure and shear stress. Furthermore, the study also reveals that the delamination is influenced by water pressure and the delamination area varies among different composite materials.
COMPOSITE STRUCTURES
(2022)
Review
Automation & Control Systems
John Henry Navarro-Devia, Yun Chen, Dzung Viet Dao, Huaizhong Li
Summary: Chatter in machining processes significantly affects surface quality and tool life, limiting higher material removal rates. Online detection of chatter and the development of new signal processing and machine condition classification approaches have been continuously studied. This paper provides a comprehensive analysis of the reported methods for sensing and testing parameter design, signal processing, and chatter indicators. It also discusses data-driven approaches, multiple sensor utilization, and the potential of machine learning. The study recommends further research on tool wear effects, chatter detection under dissimilar milling conditions, and the utilization of Big Data and machining Digital Twin for real-time chatter detection under the Industry 4.0 framework.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Green & Sustainable Science & Technology
Jun Wang, Mingyu Li, Thai Nguyen
Summary: Understanding the process of droplet formation and deposition in 3D printing is crucial for optimizing printhead design and jetting parameters. A computational study on needle-valve inkjet printing of non-Newtonian inks is presented, exploring the entire process from liquid flow inside the nozzle chamber to droplet formation and deposition. Various defects in droplet formation have been identified, and the effect of jetting parameters and nozzle design on droplet characteristics and deposition process is discussed. The study shows that precise control of droplet volume, velocity, and diameter can be achieved, allowing for improved resolution and quality in printed micro-objects.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Chengyong Wang, Zhiming Zhuang, Feng Ding, Zijian Lai, Qili Ye, Jun Wang
Summary: This study investigates the effect of impact speed and impact angle on the removal process in Fe-based amorphous alloys and establishes the corresponding abrasive erosion mechanism by considering abrasive impacts. It is found that Fe-based amorphous alloys exhibit four primary responses: shear slip, viscous flow, shear crack formation, and brittle fracture; the plasticity and brittleness of Fe-based amorphous alloys are assessed by considering the impact morphology and mechanism.
MATERIALS TODAY COMMUNICATIONS
(2023)
