Topic of Research Seminar: Study of enhancing machining performance through multi-objective optimization using RSM and Grey Relational Analysis for Inconel 718 across various cooling strategies

Abstract: Inconel 718, a nickel-based superalloy, presents significant challenges in machining due to its high strength and poor thermal conductivity, often leading to rapid tool wear and suboptimal surface finishes. This research, which investigates the machining process’s sustainability, productivity, and efficiency by turning Inconel 718 using coated carbide tools under dry, wet, and Minimum Quantity Lubrication (MQL) conditions, has direct practical implications for the field. The study evaluates the Specific Cutting Energy (SCE), Tool Wear Rate (R), Surface Roughness (Ra), and Material Removal Rate (MRR) as performance output parameters. ANOVA and regression analyses were utilized to identify the influence of cutting parameters and optimize the machining process. Key findings reveal that higher cutting speeds reduce SCE but increase tool wear due to elevated temperatures. Increasing the feed rate (f) significantly affects all response variables; higher f improves MRR but increases Ra and tool wear. Depth of cut (ap) influences SCE and Ra, with higher depths increasing material removal rates but also impacting tool wear and Ra. Results indicated that wet cooling significantly reduced R, Ra, and SCE, with optimal conditions leading to reductions of 13% in R and 6% in Ra, and a 20% improvement in SCE. MQL performed better in R and Ra than in dry machining, while dry machining exhibited lower SCE consumption. ANOVA results revealed the f as the most influential parameter, contributing 39.23%, followed by cooling conditions at 29.63%. Optimization using Grey Relational Analysis (GRA) confirms improved performance across all response variables at Vc= 75.0 m/min, f= 0.150 mm/rev, ap=0.610 mm, and “Wet” cooling conditions. This study highlights the importance of selecting appropriate cutting parameters and cooling conditions and provides practical recommendations for enhancing machining performance, with wet cooling emerging as the most effective approach.

Subject field of Topic: Turning of difficult to cut material

Name of Speaker: Muhammad Adnan Khan

Professional Rank of Speaker: PhD Student, DME/SMME

University Email of Speaker: [email protected]

Affiliation of Speaker: School of Mechanical and Manufacturing Engineering (SMME-NUST)

Date and Venue: Friday 31st Oct 2024 from 1030 to 1100 hrs in SMME conference room, School of Mechanical and Manufacturing Engineering (SMME), NUST Islamabad