Evaluation of Parameters Affecting Magnetic Abrasive Finishing (MAF) of Superalloy Inconel 718

محورهای موضوعی : Mechanical Engineering

Mehrdad Vahdati ¹ (Department of Mechanical Engineering K.N. Toosi University of Technology, Tehran, Iran)
SeyedAlireza Rasouli ² (Department of Mechanical Engineering K.N. Toosi University of Technology, Tehran, Iran)

تاریخ دریافت : 1396/03/19 تاریخ پذیرش : 1396/05/31 تاریخ انتشار : 1396/08/15

کلید واژه: Smulation, Inconel 718, Design of Experiments, Magnetic abrasive finishing, Response Surface Method,

چکیده مقاله :

Superalloys generally are among the materials with poor machinability. The removal of metal contaminations, stains, and oxides can positively affect their performance. Magnetic Abrasive Finishing (MAF) is a method which uses a magnetic field to control the material removal. As another advantage, this method can be used to polish materials such assuperalloys which have high strength and special conditions. In this paper, we investigated the magnetic abrasive finishing of nickel-base superalloy Inconel 718. Since the process is highly influenced by several effective parameters, in this study we evaluated the effects of some of these parameters such as percentage of abrasive particles, gap, rotational speed, feed rate, and the relationship between size of abrasive particles and the reduction of average surface roughness. Using Minitab software package the experiments were designed based on a statistical method. Response surface method was used as the design of the experiment. The regression equation governing the process was extracted through the assessment of effective parameters and analysis of variance. In addition, the optimum conditions of MAF were also extracted. Analysis of the outputs of MAF process experiments on IN718 revealed that gap, weight percent of abrasive particles, feed rate, rotational speed, and size of abrasive particles were the factors that affected the level of changes in surface roughness. The distance between the magnet and the work piece surface, i.e. the gap, is the most important parameter which affects the changes in surface roughness.  The surface roughness can decrease up to 62% through setting up the process at its optimum state i.e. in a rotational speed of 1453 rpm, feed rate of 10 mm/min, percentage of abrasive particles equal to 17.87%, size of particles equal to #1200, and gap size of 1 mm. There is a discrepancy of 13% between this prediction and the predicted value by the regression model. With mounting a magnet with a different pole beneath the work piece, magnetic flux density increases up to 35%.

منابع و مأخذ:

[1]    Tso, P. L., “Study on the Grinding of Inconel 718”, Journal of Materials Processing Technology, Vol. 55, No. 3, 1995, pp. 421-426.

[2]    Ezugwu, E., Bonney, J., “Finish Machining of Nickel-Base Inconel 718 Alloy With Coated Carbide Tool Under Conventional and High-Pressure Coolant Supplies”, Tribology transactions, Vol. 48, No. 1, 2005, pp. 76-81.

[3]    Öpöz, T. T., Chen, X., “Experimental Study on Single Grit Grinding of Inconel 718”, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 68, No. 1, 2014, pp. 56-65.

[4]    Aspinwall, D., Dewes, R., Ng, E. G., Sage, C., and Soo, S., “The Influence of Cutter Orientation and Workpiece Angle on Machinability When High-Speed Milling Inconel 718 Under Finishing Conditions”, International Journal of Machine Tools and Manufacture, Vol. 47, No. 12, 2007, pp. 1839-1846.

[5]    Jain, V., “Magnetic Field Assisted Abrasive Based Micro-/Nano-Finishing”, Journal of Materials Processing Technology, Vol. 209, No. 20, 2009, pp. 6022-6038.

[6]    Mulik, R. S., Pandey, P. M., “Magnetic Abrasive Finishing of Hardened AISI 52100 Steel”, The International Journal of Advanced Manufacturing Technology, Vol. 55, No. 5-8, 2011, pp. 501-515.

[7]    Girma, B., Joshi, S. S., Raghuram, M., and Balasubramaniam, R., “An Experimental Analysis of Magnetic Abrasives Finishing of Plane Surfaces”, Machining Science and Technology, Vol. 10, No. 3, 2006, pp. 323-340.

[8]    Yang, L. D., Lin, C. T., and Chow, H. M., “Optimization in MAF Operations using Taguchi Parameter Design for AISI304 Stainless Steel”, The International Journal of Advanced Manufacturing Technology, Vol. 42, No. 5-6, 2009, pp. 595-605.

[9]    Givi, M., Tehrani, A. F., and Mohammadi, A., “Polishing of the Aluminum Sheets With Magnetic Abrasive Finishing Method”, The International Journal of Advanced Manufacturing Technology, Vol. 61, No. 9-12, 2012, pp. 989-998.

[10] Kim, S., Kwak, J., “Magnetic Force Improvement and Parameter Optimization for Magnetic Abrasive Polishing of AZ31 Magnesium Alloy”, Transactions of Nonferrous Metals Society of China, Vol. 18, 2008, pp. 369-373.

[11] Kim, T. W., Kang, D. M., and Kwak, J. S., “Application of Magnetic Abrasive Polishing to Composite Materials”, Journal of Mechanical Science and Technology, Vol. 24, No. 5, 2010, pp. 1029-1034.

[12] Mun, S. D., “Micro Machining of High-Hardness Materials Using Magnetic Abrasive Grains,” International Journal of Precision Engineering and Manufacturing, Vol. 11, No. 5, 2010, pp. 763-770.

[13] Mulik, R. S., Pandey, P. M., “Magnetic Abrasive Finishing of Hardened AISI 52100 Steel”, International Journal AdvancedManufacturing Technology, Vol. 55, No. 5–8, 2011, pp. 501–515.

[14] Lin, C. T., Yang, L. D., and Chow, H. M., “Study of Magnetic Abrasive Finishing in Free-Form Surface Operations Using the Taguchi Method”, International Journal AdvancedManufacturing Technology, Vol. 34, No. 1–2, pp. 122–130, 2007.

[15] Accessed; http://www.taylor-hobson.com/.

[16] Montgomery, D. C., Design and Analysis of Experiments: John Wiley & Sons, 2008.