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https://ptsldigital.ukm.my/jspui/handle/123456789/487075Full metadata record
| DC Field | Value | Language |
|---|---|---|
| dc.contributor.advisor | Che Hassan Che Haron, Prof. Dr. | - |
| dc.contributor.author | Noureddin Abdulsalam Badroush (P75404) | - |
| dc.date.accessioned | 2023-10-11T02:28:27Z | - |
| dc.date.available | 2023-10-11T02:28:27Z | - |
| dc.date.issued | 2019-10-17 | - |
| dc.identifier.other | ukmvital:122143 | - |
| dc.identifier.uri | https://ptsldigital.ukm.my/jspui/handle/123456789/487075 | - |
| dc.description | Inconel 718 is nickel-base superalloys extensively used in aerospace engine, gas turbine, space vehicle, rocket engine, and nuclear reactor which are exposed to high stress and temperature service conditions. This requires high-level surface integrity components that are essential for high-performance, durability, and reliability of the machine parts during the performance. Although this material is widely preferred, its machinability is not at the desired level. This is due to its superior mechanical and thermal properties as well as poor thermal conductivity that inherently generates high heat and friction during the machining process and limits its machinability with rapid tool wear and poor surface integrity. Thus, this research is focused on the cutting tool performance of carbide inserts in terms of tool life and surface roughness during high speed turning Inconel 718 in dry and cryogenic (LN2) conditions. In this experimental work, a CNC turning machine was used to perform the turning process of Inconel 718 using PVD coated of TiAlN tungsten carbide (WC-6% Co) cutting tools. Response Surface Methodology (RSM) was used to develop empirical models of tool life and surface roughness using data produced by machining experiments. A Box-Behnken technique was used for fitting the response surface. The investigated turning parameters were cutting speed (75- 90- 105 m/min), feed rate (0.05- 0.12- 0.20 mm/rev) and depth of cut (0.25- 0.5- 0.75 mm. Analysis of Variance (ANOVA) was used to identify factors which significantly affect the response variables. The ANOVA analysis revealed that the cutting speed (A), depth of cut (C) and their interaction (AC) had the same significant factors affecting the tool life by 99.99%, followed by the feed rate (B) with the influence of 99.93% in both cutting conditions. For the surface roughness, it was significantly influenced by cutting speed (A) followed by quadratic feed rate and feed rate (B) when being cut under cryogenic. Meanwhile, under dry condition, cutting speed, depth of cut, quadratic feed rate and the interaction (AB) were the most significant factors which had the same rate of influence. The results obtained from the experiments showed that the application of cryogenic cooling helps to improve the tool life up to 53% compared to dry turning especially at lower cutting speed. The dominant types of wear found were flank wear, crater wear, fracture wear, plucking, notching, and built up edge (BUE). Through SEM observations and EDX analysis of the tested inserts, it was shown that the dominant wear mechanisms were adhesion and abrasion due to chemical affinity between the elements from the workpiece and insert and the presence of hard particles. It was also shown that cryogenic machining improved the roughness of machined surface by 35% compared to dry machining. The depth of the affected microstructure increased as the cutting speed and feed rate were increased, and the changes of microstructure of the specimens produced under cryogenic condition were less severe than dry cutting. For the micro-hardness beneath the machined surface, it was found to increase as it was affected by the extreme cooling effect of the cryogenic coolant with higher hardness value than in dry condition. In cryogenic cooling, chip thickness increased at all three cutting parameters compared to dry machining. The pitch of chip formed by cryogenic turning was larger than dry turning and it became smaller when a higher level of speed was applied. From this research, the application of cryogenic coolant enhanced the quality of machining outputs in term of surface integrity and cutting tool performance. This finding is very useful for the aerospace industry where accuracy is the most important aspect in their manufacturing.,Ph.D. | - |
| dc.language.iso | eng | - |
| dc.publisher | UKM, Bangi | - |
| dc.relation | Faculty of Engineering and Built Environment / Fakulti Kejuruteraan dan Alam Bina | - |
| dc.rights | UKM | - |
| dc.subject | Universiti Kebangsaan Malaysia -- Dissertations | - |
| dc.subject | Dissertations, Academic -- Malaysia | - |
| dc.subject | Carbide cutting tools | - |
| dc.subject | Cutting tools | - |
| dc.subject | Nickel alloys | - |
| dc.title | Performance of carbide tools and surface integrityof inconel alloy 718 in cryogenic and dry machining | - |
| dc.type | Theses | - |
| dc.format.pages | 196 | - |
| dc.identifier.callno | TJ1186.B333 2019 3 tesis | - |
| dc.identifier.barcode | 005552(2021)(PL2) | - |
| Appears in Collections: | Faculty of Engineering and Built Environment / Fakulti Kejuruteraan dan Alam Bina | |
Files in This Item:
| File | Description | Size | Format | |
|---|---|---|---|---|
| ukmvital_122143+SOURCE1+SOURCE1.0.PDF Restricted Access | 4.7 MB | Adobe PDF |  View/Open |
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