INCREASE PRODUCTIVITY OF HARD-TO-MACHINE MATERIALS BY PREVENTIVE HEATING OF THE WORKPIECE

Received: April 23, 2024
Revised: May 08, 2024
Accepted: May 09, 2024
1
Lviv Polytechnic National University
2
Department of Robotics and Integrated Mechanical Engineering Technologies, Lviv Polytechnic National University
3
Lviv Polytechnic National University

The possibility of increasing productivity by increasing the cutting parameters of difficult-to-machine materials, using expensive tool materials, etc. is an extensive trend of innovative improvement and is accompanied by high costs of operations and the need to provide expensive equipment. The article argues that a more effective method of improving machining operations is the use of the workpiece Turning with Preventive Heating (TPH) method. An analysis of existing methods, advantages and disadvantages of heating the cutting zone of the workpiece for machining certain difficult-to-machine materials is presented. The stages of studying the power, thermodynamic, and stress-strain state of the workpiece resulting from the complex action of mechanical loads associated with shearing of the processed material during cutting and thermal loads created by TPH technology are recommended. Modern programs for simulation analysis of innovative cutting processes are analyzed. Arguments for the effective use of AdvantEdge software in comparison with similar alternative programs for simulating the processes of machining difficult-to-machine materials are presented. The results of studies of changes in cutting forces for different cases of preventive heating of the cutting zone of parts made of the chromium-nickel alloy Inconel 718 are presented

  1. K. Wegener, F. Kuster, S. Weikert, L. Weiss, and J. Stirnimann, “Success Story Cutting”, Procedia CIRP, vol. 46, pp. 512-524, 2016.
  2. V. Astakhov, “Machining of Hard Materials – Definitions and Industrial Applications”, in: J. Davim, (eds) Machining of Hard Materials, Springer, London, 2011.
  3. H. Zheng and K. Liu, “Machinability of Engineering Materials”, in: A. Nee (eds), Handbook of Manufacturing Engineering and Technology, Springer, London, 2013.
  4. P.S. Gowthaman, S. Jeyakumar, and B.A. Saravanan, “Machinability and tool wear mechanism of Duplex stainless steel – A review”, Materials Today: Proceedings, vol. 26, no. 2, pp. 1423-1429, 2020.
  5. S. Liao and J. Duffy, “Adiabatic shear bands in a TI-6Al-4V titanium alloy”, Journal of the Mechanics and Physics of Solids, vol. 46, iss. 11, pp. 2201-2231, 1998.
  6. W. F. Sales, J. Schoop, L. R. R. da Silva, Á. R. Machado and I.S. Jawahir, “A review of surface integrity in machining of hardened steels”, Journal of Manufacturing Processes, vol. 58, pp. 136-162, 2020.
  7. L.G. Korshunov, and N.L. Chernenko, “Structural Transformations and Tribological Effects in the Surface Layer of Austenitic Chrome-Nickel Steel Initiated by Nanostructuring and Oxidation”, J. Surf. Investig, vol. 14, pp. 632–638, 2020.
  8. B. Maher, V. Wagner, G. Dessein, J Sallabery, and D. Lallement, “An Experimental Investigation of Hot Machining with Induction to Improve Ti-5553 Machinability”, Applied Mechanics and  Materials, vol. 62, pp. 67-76, 2011.
  9. G. Madhavulu, and A. Basheer, “Hot Machining Process for improved metal removal rates in turning operations”, Journal of Materials Processing Technology, vol. 44, no. 3–4, pp. 199-206, 1994.
  10. S. Goel, W. Bin, X. Luo, A.Agrawal, and V. K. Jain, “A Theoretical Assessment of Surface Defect Machining and Hot Machining of Nanocrystalline Silicon Carbide”, ASME. J. Manuf. Sci. Eng., vol. 136(2): 021015, 2014.
  11. A.A. Elsadek, A.M. Gaafer, S.S.Mohamed, et al. “Prediction and optimization of cutting temperature on hard-turning of AISI H13 hot work steel”, SN Appl. Sci., vol. 2, no. 540, 2020.
  12. F. Egorov, “Hot Machining: Utilisation of the Forging Heat for Efficient Turning at Elevated Temperatures”, Advanced Materials Research., vol. 769, pp. 93-100, 2013.
  13. G. Madhavulu and B. Ahmed, “Hot Machining Process for improved Metal Removal Rates  in  turning operations”, Int. J. of Mater. Process Technol., vol. 44, pp. 199-206, 1994.
  14.  M. Dwami, and M. Zadshakoyan, “Investigation of Tool Temperature and Surface Quality in Hot machining of Hard to Cut”,  Int. J. of World Academy of Science and Technology, vol. 46, pp. 10-27, 2008.
  15. N. Tosun, and L. Ozler, “Optimization for hot turning operations with multiple performance characteristics”, Int. J. Adv. Manuf. Technology, vol. 23, pp. 777-782, 2004.
  16. K. R. Haapala, F. Zhao, J. Camelio, J. W. Sutherland, S. J. et al., “A Review of Engineering Research in Sustainable Manufacturing”, ASME. J. Manuf. Sci. Eng., vol. 135(4): 041013, 2013.
  17. S.K. Thandra, S.K. Choudhury, “Effect of cutting parameters on cutting force, surface finish and tool wear in hot machining”, International Journal of Machining and Machinability of Materials (IJMMM), vol. 7, no. 3/4, pp. 260 – 273, 2010.
  18. V. Upadhyay, P. K Jain and N. K. Mehta, “Machinability Studies in Hot Machining of Ti-6Al-4V Alloy”, Advanced Materials Research, vol. 622–623, pp. 361–365, 2012
  19. G. Talla, S. Gangopadhayay, C. Biswas, “State of the art in powder-mixed electric discharge machining: A review”, Journal of Engineering Manufacture, vol. 231(14), pp. 2511-2526, 2017.
  20. M. Davami, M. Zadshakoyan, “Investigation of tool temperature and surface quality in hot machining of hard-to-cut materials”, International Journal of Materials and Metallurgical Engineering, vol. 2(10), pp. 252-256, 2008.
  21. K.P. Maity and P.K. Swain, “An experimental investigation of hot-machining to predict tool life”, Journal of Materials Processing Technology, vol. 198, no. 1–3, pp. 344-349, 2008.
  22. A. K. Parida, “Analysis of chip geometry in hot machining of Inconel 718 alloy”, Iranian Journal of Science and Technology, vol. 43, pp. 155-164, 2019.
  23. S. Ranganathan, and T. Senthilvelan, “Optimizing the process parameters on tool wear of WC insert when hot turning of AISI 316 stainless steel”, Journal of Engineering and Applied Sciences, vol. 5(7), pp. 24-35, 2010.
  24. A.K. Parida, and K. P. Maity, “An experimental investigation to optimize multi-response characteristics of Ni-hard material using hot machining”, Advanced Engineering Forum, pp. 16-23, 2016.
  25. L. Ozler , A. Inan, C. Ozel, “Theoretical and experimental determination of tool life in hot machining of austenitic manganese steel”, International Journal of Machine Tools & Manufacture, vol. 41, pp.163–172, 2001.
  26. A. Melhaoui, “Contribution study of cutting tool wear during laser assisted machining and machinability of ceramics (zinc oxide)”, PhD thesis, École Centrale de Paris, 1997.
  27. H. K. Versteeg, “An introduction to computational fluid dynamics the finite volume method”, Pearson Education India, 2007.
  28. A.K. Parida, and K. P. Maity, “Optimization in hot turning of nickel based alloy using desirability function analysis”, International Journal of Engineering Research in Africa, vol. 24, pp. 64-70, 2016.
  29. M. Baili, V. Wagner, G. Dessein, J. Sallaberry, and D. Lallement, “An experimental investigation of hot machining with induction to improve Ti-5553 machinability”, Applied mechanics and Materials, vol. 62, pp. 67-76, 2011.
  30. C. E. Leshock, J. N. Kim, and Y. C. Shin, “Plasma enhanced machining of Inconel 718: modeling of workpiece temperature with plasma heating and experimental results”, International Journal of Machine Tools and Manufacture, vol. 41(6), pp. 877-897, 2001.
  31. K. S. Kim, C. M. Lee, “Prediction of preheating conditions for inclined laser assisted machining”, Journal of Central South University, vol. 19(11), pp. 3079-3083, 2012.
  32. A. K. Parida and K. Maity, “Numerical and experimental analysis of specific cutting energy in hot turning of Inconel 718”, Measurement, vol. 133, pp. 361-369, 2019.
  33. H. Ding and Y.C. Shin, “Laser-assisted of hardened steel parts with surface integrity analysis”, International Journal of Machine Tools and Manufacture, vol. 50, pp.106-114, 2010.
  34. M. Lanzetta, A. Gharibi, M. Picchi Scardaoni, and C. Vivaldi, “FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features”, Materials, vol. 14(14): 3789, 2021.