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ABSTRACT
Nickel-base superalloy Inconel 718 is a high-strength, thermal-resistant. Because of its
excellent mechanical properties, it plays an important part in recent years in aerospace,
petroleum and nuclear energy industries. Due to the extreme toughness and work hardening
characteristic of the alloy, the problem of machining Inconel 718 is one of ever-increasing
magnitude. This investigation optimized the machining characteristics of Inconel 718 bars
using tungsten carbide and cermet cutting tools. The approach is based on Taguchi method,
the signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) are employed to study
the performance characteristics in turning operations. The roundness and flank wear of the
ultrasonically and conventionally machined workpieces were measured and compared.
Through this study the optimal cutting parameters for turning operations can be obtained.
Key words: Inconel 718; Ultrasonic; Taguchi method; Flank wear; Roundness
the relevant literature [4,5] and practical best” (NB), and “higher is better” (HB). The
cutting tests, this study selected three cutting S/N ratios were calculated using the
tools, TN35, CT3000 and NX2525, as listed following equations [12]:
in Table 2. This study takes tangent direction S
η = 10 log( ratio) (1)
as the direction of ultrasonic vibration aided N
cutting. S 1
HB: ratio) = 2
(
The Taguchi method is a powerful tool N σ
for designing high quality systems. To 1 1 1 1
σ 2 = ( 2 + 2 + ..... + 2 ) (2)
increase the experimental efficiency, the n y1 y2 yn
L18 mixed orthogonal table in the Taguchi S 1
LB: ( ratio) = 2
quality design [10] is used to determine the N σ
significant machining factors. In the 1
σ 2 = ( y1 2 + y 2 2 + .... + y n 2 )
(3)
experiments, we select six influential n
machining parameters, such as cutting tools Where η denotes the observed value, i.e.,
of different materials, depth of cut, cutting the calculated value of the S/N ratio (unit:
speed, feed rate, working temperature and dB), y n represents the observed value and
ultrasonic power, each of which has three n is the repeated number.
different levels (high, medium and low Table 4(a) lists the experimental results
levels), as shown in Table 3. The machining for roundness and the corresponding
characteristics studied include roundness of signal-noise ratios (S/N) using Eqs.(1) and
the workpiece, and flank wear of the tools. (3). The mean S/N ratio for each level of the
By adjusting experimental combinations and cutting parameters is summarized and called
analyzing experimental results, this work the S/N response table for roundness, the
leads to the optimum cutting parameters. L18 experiments is also calculated and
illustrated in Table 4(b). Fig. 1 shows the
3. Results and analysis of the S/N response graph for roundness, and
experimental indicates that roundness without influence
3.1 Analysis of the S/N ratio from cutting tools, and a smaller feed rate
Classical experimental design methods can obtain better roundness.
are too complex and not easy to use. To To examining the influence of
solve this problem, the Taguchi method uses ultrasonic-aided cutting on roundness, two
a special design of orthogonal arrays to level conjunctions of No.17 and No.18,
study the entire parameter space with a listed in Table 4(a), were used for
small number of experiments [11]. The experiment, and represent the maximum and
Taguchi method employs a generic minimum roundness combinations,
signal-to-noise (S/N) ratio to quantify the respectively, among 18 experimental
present variation. Depending on the combinations. In Table 4(c), the
particular type of characteristics involved, experimental conditions of No.17 and No.18,
different S/N ratios may be applicable, No.17-1 and No.18-1 are cutting with and
including “lower is better” (LB), “nominal is without ultrasonic aid, which obtained
龍華科技大學學報第二十一期,2006.09
average roundness values of 10.03μm and the application of ultrasonic vibration can
1.97 μ m, 12.2 μ m and 3.63 μ m, improve the flank wear quality considerably.
respectively. The results obtained show that Improvements of up to 26.52- 46.26 % have
the application of ultrasonic vibration can been achieved.
improve the roundness quality considerably. Figs. 3(a) and (c) show ultrasonically
Improvements of up to 17.78- 45.73% have aided cutting, which could obtain a low
been achieved. flank wear of the cutter. Moreover, the BUE
This work used an optical microscope occurs at TN35 tungsten carbide, as shown
and the Optimas software to inspect the in Figs. 3(a) and (b), and is not found at
flank wear. Table 5(a) lists the experimental NX2525 cermet, as illustrated in Figs. 3(c),
results for flank wear and S/N ratios, while (d) and the cutting tool of the NX2525
Table 5(b) and Fig. 2 show the S/N response cermet can obtain a low flank wear (Fig. 2).
table and S/N response graph for flank wear. 3.2 Analysis of variance (ANOVA)
Fig. 2 indicated that using a cermet cutting The purpose of the ANOVA is to
tool NX2525 produces smaller flank wear, investigate the design parameters that
and that the flank wear decreases with significantly affect the quality characteristic.
decreasing cut depth. The total sum of square SST from the S/N
Generally, most materials soften with ratio η can be calculated as [13] :
n
heating to high temperature. However, at an
appropriate temperature, Inconel 718
SST = ∑ (η
i =1
i −ηm )2 (4)
precipitates the hard second phase ofγ〃 Where n is the number of experiments in the
(Ni3Nb), increasing the difficulty of cutting. orthogonal array and η i is the mean S/N
Observing the working temperatures level in ratio for the i th experiment. The sum of
Figs. 2 reveals that when a workpiece is squares from the tested parameter SSP can be
heated for high-temperature (190℃) cutting, calculated as :
the flank wear increases with temperature.
( Sη j ) 2
2
t
1⎡ n ⎤
To inspect the effect of ultrasonic-aided SSP = ∑
j =1 t
− ⎢∑η i ⎥
n ⎣ i =1 ⎦
(5)
cutting on flank wear, this investigation
chooses two combinations of No.3 and Where p represents one of the tested
No.17 in Table 5(a) for an experiment, parameters, j the level number of this
where these two combinations represent the parameter p, t the repetition of of each level
maximum and minimum flank wear
of the parameter p, Sη j the sum of the S/N
combinations, respectively, from among 18
combinations examined in the experiment. ratio involving this parameter p and level j.
In Table 5(c), the experimental conditions of The sum of squares from error
No.3 and No.17, No.3-1 and No.17-1 are parameters, SSe is
cutting with and without ultrasonic aid, and SSe =SST – SSA – SSB – SSC (6)
the flank wear measurements are 28.15mm2 The total degrees of freedom is DT = m-1,
and 1.51mm2, 38.31mm2 and 2.81mm2, where the degrees of freedom of the tested
respectively. The results obtained show that parameter DP = t-1. The variance of the
Application of Taguchi method in the optimization of cutting parameters for turning operations
parameter tested is VP=SSP/DP. Then, the where Ym is the total mean S/N ratio, Yi
F-value for each design parameter is simply is the mean S/N ratio at the optimal level,
the ratio of the mean-of-squares deviations and k is the number of the main design
to the mean of the squared error (FP=VP/Ve). parameters that affect the quality
* characteristic. The measuring data and the
The corrected sum of squares S P can be
actual S/N ratio of confirmation experiments
calculated as: are listed in Table 7. The largest S/N ratios
* in the L18 factors combinations of the two
S P = SSP – DPVe (7)
types of machining characteristics
The percentage contribution ρ can be were –5.92 (Table 4(a)) and –3.61 (Table
calculated as : 5(a)), respectively. However, the S/N ratios
* of confirmation experiments are –4.59
S
ρP = P (8) and –2.10, and both are larger than the
SS T
above two. In addition, the S/N prediction,
Table 6 shows the results of ANOVA -5.04 and –1.70, are very close to the actual
for the roundness and the flank wear. It is value. This finding indicated that the
found that depth of cut is the most experiments in this study possess excellent
significant cutting parameters affecting the repetitiveness and great potential for future
roundness. The change of the cutting speed references.
and cutting tools are the insignificant effect
on roundness of the machined workpiece. 4. Conclusion
The results of ANOVA for flank wear (Table
This paper has discussed an application
6). The contribution order of the cutting
of the Taguchi method for optimizing the
parameters for flank wear is cutting tools for
cutting parameters in turning Inconel 718
different materials, then working
operations. This study discusses six
temperature, then ultrasonic power and then
machining parameters, including cutting
depth of cut.
tools for different materials, depth of cut,
cutting speed, feed rate, working
3.3 Confirmation experiments
temperature and ultrasonic power. The
Once the optimal level of the design
machining characteristics studied include
parameters has been selected, the final step
roundness and flank wear. The conclusions
is to predict and verify the improvement of
of this study may be summarized as
the quality characteristic using the optimal
follows :
level of the design parameters. The
1. Formation of built-up-edge (BUE) when
estimated S/N ratio Ypredicted using the
using a NX2525 cermet cutter is far less
optimal level of the design parameters can
than a TN35 tungsten carbide cutter, and
be calculated as [14] :
the measured flank wear is lower than
k
Ypredicted = Ym + ∑ (Yi − Ym ) (9) for a TN35 tungsten carbide cutter.
i =1
2. When the workpiece underwent high
龍華科技大學學報第二十一期,2006.09
Table 4(c). An analysis of roundness with and without ultrasonic aid cutting
Experiment Factors Roundness (μm) Mean Improve
value ment.
No. ( μ m) rate
T D S F Temp P Rd1 Rd2 Rd3
(%)
17 3 2 1 3 1 2 11.80 10.20 8.10 10.03 17.78
17-1 3 2 1 3 1 13.10 11.60 11.90 12.20
18 3 3 2 1 2 3 2.00 2.20 1.70 1.97 45.73
18-1 3 3 2 1 2 5.40 1.70 3.80 3.63
Table 5(a). Experimental results for flank wear and S/N ratio
Experiment Factors Flank wear (mm2) S/N
No. T D S F Temp. P A1 A2 A3 (dB)
T D S F Temp. P
Table 5(c). An analysis of flank wear with and without ultrasonic aid cutting
Experiment Factors Flank wear (mm2) Mean Improvement
value rate (%)
No. T D S F Temp P R1 R2 R3 (mm 2
)
Table 6 Results of the ANOVA for the roundness and the flank wear
Factor Roundness Factor Flank wear
SS DOF Var F ratio σ(%) SS DOF Var F ratio σ(%)
T 5.56 2 2.78 1.31 2.06 T 879.62 2 439.81 23.97 31.29
D 88.98 2 44.49 20.90 32.96 D 279.18 2 139.59 7.61 9.93
S 1.87 2 0.93 0.44 0.7 S 54.02 2 27.01 1.47 1.92
F 32.89 2 16.45 7.73 12.18 F 51.72 2 25.86 1.41 1.84
Temp. 19.37 2 9.69 4.65 7.17 Temp. 472.29 2 236.14 12.87 16.8
P 34.05 2 17.03 8.00 12.6 P 321.67 2 160.83 8.77 11.44
Error 87.26 41 2.13 32.32 Error 752.24 41 18.35 26.76
Total 269.98 53 100 Total 2810.75 53 100
Note 1: T= Cutter; D= Depth of cut; S= Cutting speed; F= Feed rate; Temp. =Working
temperature; P= Ultrasonic power; σ= Contribution
Note 2: The F ratios according to the F distribution table for roundness is
F(0.05, 2, 41)=3.2
The F ratios according to the F distribution table for flank wear is
F(0.01, 2, 41)=5.2
Application of Taguchi method in the optimization of cutting parameters for turning operations
Table 7 Results of the confirmation experiment for the surface roughness and
the cutting force
Control factors S/N (dB) Confirmation experiments
prediction
T D S F Temp. P Measuring Mean S/N
data value (dB)
Roundness CT3000 0.3 43 0.054 190℃ 180
mm m/min mm/rev Watt -5.04 1.75 1.90 1.40 1.68 -4.59
flank wear NX2525 0.1 22 0.103 25℃ 140
mm m/min mm/rev Watt -1.70 1.24 1.08 1.47 1.26 -2.10
-6
-8
S/N ratio of roundness (db)
-10
-12
-14
-16
-18
-7
-9
S/N ratio of flank wear (db)
-11
-13
-15
-17
-19
-21
100μm
100μm
(a). Cutting with ultrasonic aid (b). Cutting without ultrasonic aid
Cutting tool: TN35, Depth of cut: Cutting tool:TN35, Depth of cut:
0.3mm 0.3mm
Cutting speed: 73m/min, Feed: Cuttingspeed:73m/min,Feed:
0.147mm/rev. 0.147mm/rev.
Working temp.: 190℃ Working temp.: 190℃
Ultra. Power: 180 Watt, Frequency: Ultra. Power: 0, Frequency: 0
20KHz Flank wear area: 23.91mm2
Flank wear area: 15.33mm2
Flank wear zone No BUE
Flank wear zone No BUE
100μm
100μm
(c). Cutting with ultrasonic aid (d). Cutting without ultrasonic aid
Cutting tool: NX2525, Depth of cut: Cutting tool:NX2525,Depth of cut:
0.2mm 0.2mm
Cutting speed: 22m/min, Feed: Cutting speed: 22m/min, Feed:
0.147mm/rev. 0.147mm/rev.
Working temp.: 25℃ Working temp.: 25℃
Ultra. Power: 160 Watt, Frequency: Ultra. Power: 0, Frequency: 0
20KHz
Flank wear area: 3.45 mm2
2
Flank wear area: 1.36 mm
Figure 3. Comparisons of flank wear with and without ultrasonic aid cutting
龍華科技大學學報第二十一期,2006.09
應用田口實驗法尋求最佳車削參數之研究
1 2
龍華科技大學 機械系 華夏技術學院 機械系
摘要
Inconel 718 為析出硬化型鎳基高溫超合金(Ni-Base Superalloy),在-250~700
℃之超低溫及中高溫環境具有優良的機械性質,近年來廣泛應用在航太零組件、石化及
核能反應器等工業上。Inconel 718 合金具有沃斯田鐵型的基地,其中鈮(Nb)之含量又
較其他耐熱超合金高,在切削壓力及熱量輸入時容易析出γ〞(Ni3Nb)之堅硬二次相,造
成切削時嚴重之加工硬化進而導致刀具磨耗,母材優異的機械性質,使得金屬移除率較
低,從鎳基超合金發展以來,其加工效率一直是專家學者研究的重點。本研究的目的為
應用田口實驗計畫法,以碳化鎢及瓷金為刀具,配合超音波輔助振動及工件加熱進行高
溫切削,尋求 Inconel 718 的最佳切削參數。文中比較使用及不使用超音波輔助振動,
對工件真圓度及刀腹磨耗的改善程度。經由本研究結果獲得最佳車削 Inconel 718 的參
數組合。
關鍵字: 鎳基高溫超合金、超音波振動、田口實驗法、刀腹磨耗、真圓度