INTERNATIONAL JOURNAL OF MECHANICAL (IJMET), ISSN 0976 International Journal of Mechanical Engineering and Technology ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME AND TECHNOLOGY (IJMET)
ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 3, September - December (2012), pp. 294-305 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2012): 3.8071 (Calculated by GISI) www.jifactor.com

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PREDICTION OF OPTIMAL CUTTING PARAMETERS FOR HIGH SPEED DRY TURNING OF INCONEL 718 USING GONNS
1

Satyanarayana.B, 2Ranga Janardhana.G, 3Hanumantha Rao.D, and 4 Kalyan.R.R.

1,4

Department of Mechanical Engineering, VNR Vignana Jyothi Institute of Engineering & Technology, Hyderabad, India, E-mail: sanbollu@gmail.com 2 Principal, College of Engineering, J N T U, Vizayanagaram, India, E-mail: ranga.janardhana@gmail.com 3 Principal, Matrusri Engineering College, Hyderabad, India, E-mail: dharwada.rao@gmail.com

ABSTRACT Inconel 718, a Fe-Ni based super alloy widely used in the aircraft industry for its capacity to keep mechanical properties at high temperatures. Characteristics like lower thermal conductivity, work hardening make Inconel 718 a difficult-to-cut material. The Genetically Optimized Neural Network System (GONNS) is proposed for the prediction of optimal cutting conditions, in high speed dry turning of Inconel 718 using three types of tungsten carbide tools, to obtain the best results than other mathematical models. GONNS uses Back propagation (BP) type Neural Networks (NN), which is Genetically Optimized, to establish the relationship between input and output parameters. Optimal cutting conditions are then obtained from the generated NN model. GONNS was used in two case studies for prediction of optimal cutting parameters i) To keep the cutting forces minimum ii) To obtain the best possible surface roughness. Sensitivity test was also conducted to study the influence of cutting parameters. Keywords: Inconel 718, High speed turning, Neural Networks, Genetic Algorithm

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1. INTRODUCTION Propulsion systems for next generation aircrafts must perform with high efficiency and must meet strict environmental regulations. In the due course of achieving these requirements, necessity of superior materials has been emerged. This lead to materials with superior properties and high heat resistance such as nickel- and titanium-based alloys and named as super alloys. The introduction of these materials in the aero-engine has led to a remarkable increase in engine efficiency [1]. Inconel 718, which is a Fe-Ni based super alloy, for its several unique properties is essentially used in aerospace. The unique and desirable heat-resistant and work hardening characteristics of super alloys on the other hand impair their machinability due to the extremely high temperature generated at the cutting edge [1]. This tends to deform the cutting tool, leading to accelerated wear during machining, making Inconel 718 a difficult-to-cut material [2, 3]. Good wear resistance, High hot hardness, High strength and toughness are requirements for any cutting tool in machining Inconel 718. [4]. Advances in cutting tool technology have led to the introduction of coated and uncoated carbide, ceramic, CBN/PCBN and PCD tools with adequate hot hardness and toughness to withstand elevated temperatures. The development of governmental pollution-preventing initiatives has lead to attention to the role of cutting fluids in machining. At high cutting speeds, it is well known that the lubrication in the cutting zone is not evident and not really effective. That is why high speed machining and dry machining are often associated. Thus High speed dry machining leads to lower cutting forces, higher removal rates and to lower energy consumption [5] making it suitable for Inconel 718. The modeling and monitoring of machining operations is gaining importance. In any machining operation, it is an important task to select cutting parameters for achieving highquality cutting performance [6]. Optimum selection of cutting conditions importantly contributes to the increase of productivity and the reduction of costs [7]. A good understanding of the behavior and the relationship between the workpiece materials, cutting tool materials, cutting conditions and the process parameters is an essential requirement for the optimization of the cutting process [8]. Artificial neural networks (ANNs) are one of the most powerful computer modeling techniques, based on statistical approach. ANNs have been extensively applied in modeling many metal-cutting operations such as turning, milling, and drilling [9]. Genetic Optimization allows virtually optimizing any parameter in a neural network to increase the performance such as NN weights [10]. Very limited or no work has been done in optimizing high-speed machining of Inconel 718 by Genetically Optimized NN System (GONNS). 2 MODEL DESCRIPTION 2.1 Genetic Optimization-based Neural Network Artificial neural networks (ANN) are currently being used in a variety of applications with great success [1]. Back-propagation (BP) is one of the best and uses the unique learning principle which of minimizing of errors in neural network output. Genetic algorithm (GA), which is one of the Evolutionary Algorithms (EA), exploits the idea of survival of fitness and an interbreeding population and creates a novel and innovative strategy.

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Figure 1 Combination of Genetic Algorithm and Neural Network (in part adapted) from [10 p. 29] twork [10, e One of the most promising techniques is the adaptation of network training with EA. The merging of EA and ANN will gain adaptability to dynamic environment and will lead to significantly better intelligent systems than relying on ANN, PSO, or GA. In this pap a GApaper, based neural network (GA-NN) model (Fig.1) was framed to optimize the turning process. ANN NN) (Fig.1) will acquire the optimal weights using GA which leads to a high performance network with minimal errors -NN) developed for optimization 2.2 Steps in hybrid model (GAThe NN to be genetically optimized during training and testing, which means that Mean Squared Error of weights generation is optimized resulting in less error percentages. The steps involved in the process are as follows. 1. Collection of experimental data set of inputs and outputs (in excel sheets) in machining tal Inconel 718. 2. Providing these input and output pool to software tool (Nuero Solutions 5.1) [11] in a jumbled software [11 fashion. 3. Tag the data in software as inputs, outputs, training, testing and production. (Tagging is to production. assist the software while developing model in step 5) 4. Create a custom network of required structure and save it. 5. Further, train and test the network. The data tagged as train will be used for training; similarly other operations will be done. This will generate the required model. s 6. Selection of optimal parameters: After developing NN system, end relation can be optimized in GA using MATLAB to find out the best optimal parameters for machining. 7. Sensitivity Analysis: This is analogues to ANOVA which shows the influence of cutting analogues parameters on outputs. 3. EXPERIMENTAL WORK 3.1 Machining parameters From survey, the tool is used at the rated cutting speed only 58% of the time, and only 38% of the tools are used up to the full tool life capability [12] showing that selected cutting their ] speeds are far below the optimal economic speeds. Several factors influence the final surface roughness and cutting force in turning operation such as spindle speed, feed rate, and depth of cut. These cutting conditions can be setup in advance to have best results [12].The most se [12 important parameters, that effect surface roughness and cutting force are cutting feed, depth of cut, and spindle speed. Hence these parameters are chosen as cutting parameter Preliminary parameters. experiments were carried out to fix the limits of these parameters based on the machining data on Inconel 718 from hand books and literature.
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Table 1 Parameters and their limits. Tool Material Cutting Feed (mm/rev) DOC Speed (mm) (m/min) 50,60,70 0.103,0.137,0.164 0.5,0.75,0.1 Uncoated WC 50,60,70 0.103,0.137,0.164 0.5,0.75,0.1 TiN/TiAlN PVD coated TiN/Al2O3/Ti(CN) CVD coated 50,60,70 0.103,0.137,0.164 0.5,0.75,0.1 3.2 Work piece and Tools The billets used were Inconel 718 rods (Ni = 54.48 %, Cr = 17.5%, Nb = 4.9%, Al = (Ni 0.66 %, Ti = 0.96% balance are Fe and other) with 30 mm diameter whose Tensile Yield strength is 1100 Mpa. Considering economical advantages, Un Coated carbide tool of H13A Un-Coated grade, CVD coated tool of TM4000 grade and PVD coated tool of TS 2000 grade were selected. The tool signature of the same is presented in Table 2 2. Table 2 Tool Nomenclature
Clearan ce Inclinatio Approac n h angle angle () angle () () 6 -6 75 Inclu ded angle () 90

Rake angle ()o -6

Nose Radius (r)mm 0.8

3.3 Machining Turning operations were carried out on a conventional lathe of bed width 242 mm and a Speed range of 45-2000 RPM. This lathe is provided with three component strain gauge 2000 dynamometer and a high quality feed mechanism which maintains the set feed accurately. maintains Turning trials were carried out on super alloy Inconel 718 material in dry conditions follo following L27 Orthogonal Array [13].

Figure 2 Inconel 718 billet Figure 3 Experimental Set-up 4. MACHINING PERFORMANCE MEAS MEASURE It has been recognized that the reliable quantitative predictions are essential to develop optimization strategies for selecting cutting conditions. Unfortunately there is a lack of information dealing with test methodology and data evaluation in metal cutting experiments [14]. l [14

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Figure 4 Surface Roughness Tester

Figure 5 Three component strain gauge dynamometer

Roughness plays an important role in determining how a real object will interact with its environment. Irregularities in the surface may form nucleation sites for cracks or corrosion. [15]. onment. sites [15 Therefore appropriate cutting conditions are to be established to reach the required quality. Hence, surface roughness is chosen in our study and was measured by Mitutoyo make SJ201 Surface Roughness tester (Fig.4). ). Knowledge of the cutting forces is essential for Proper design of the cutting tools and cutting tool and Calculation of the machine tool power. Thus need for a good predictive model of cutting tion conditions to control cutting force has been identified. The simplest way to control cutting forces ns is to change the cutting conditions. The main cutting force has been noted using strain gauge dynamometer shown in the figure 5 ynamometer 5.
5. EXPERIMENTAL RESULTS

5.1 Surface Roughness results Table 3 Experimental layout using standard L27 orthogonal array with experimental results for uncoated tool
Test No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Speed [m/min] 50 50 50 50 50 50 50 50 50 60 60 60 60 60 60 60 60 60 70 70 70 70 70 70 70 70 70 Feed [mm/rev] 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 DOC [mm] 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 SR [m] 0.734 0.707 0.679 0.929 0.9016 0.874 1.083 1.056 1.028 0.830 0.802 0.775 1.025 0.997 0.969 1.179 1.152 1.124 0.926 0.898 0.871 1.120 1.093 1.065 1.275 1.247 1.220

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Table 4 Experimental layout using standard L27 orthogonal array with experimental results for coated tool (PVD)
Test No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Speed [m/min] 50 50 50 50 50 50 50 50 50 60 60 60 60 60 60 60 60 60 70 70 70 70 70 70 70 70 70 Feed [mm/rev] 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 DOC [mm] 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 SR [m] 0.641 0.614 0.586 0.836 0.808 0.781 0.990 0.963 0.935 0.737 0.709 0.682 0.932 0.904 0.876 1.086 1.059 1.031 0.833 0.805 0.778 1.027 1.001 0.972 1.182 1.154 1.127

Table 5 Experimental layout using standard L27 orthogonal array with experimental results for coated tool (CVD)
Test No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Speed [m/min] 50 50 50 50 50 50 50 50 50 60 60 60 60 60 60 60 60 60 70 70 70 70 70 70 70 70 70 Feed [mm/rev] 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 DOC [mm] 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 SR [m] 0.708 0.681 0.653 0.903 0.875 0.848 1.057 1.030 1.002 0.804 0.776 0.749 0.999 0.971 0.943 1.153 1.126 1.098 0.900 0.872 0.845 1.094 1.067 1.03974 1.24 1.22 1.194

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME

5.2 Cutting Force results Table 6 Experimental layout using standard L27 orthogonal array with experimental results for uncoated tool
Test No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Speed [m/min] 50 50 50 50 50 50 50 50 50 60 60 60 60 60 60 60 60 60 70 70 70 70 70 70 70 70 70 Feed [mm/rev] 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 DOC [mm] 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 CF [N] 74 348 622 235 509 783 364 637 911 60 213 487 100 374 648 229 502 776 195 78 352 34 239 513 94 367 641

Table 7 Experimental layout using standard L27 orthogonal array with experimental results for coated tool (PVD)
Test No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Speed [m/min] 50 50 50 50 50 50 50 50 50 60 60 60 60 60 60 60 60 60 70 70 70 70 70 70 70 70 70 Feed [mm/rev] 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 DOC [mm] 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 CF [N] 61 335 60 222 496 770 350 624 898 73 200 474 87 361 635 215 489 763 208 65 339 47 226 500 80 354 628

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME
Table 8 Experimental layout using standard L27 orthogonal array with experimental results for coated tool (CVD)
Test No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Speed [m/min] 50 50 50 50 50 50 50 50 50 60 60 60 60 60 60 60 60 60 70 70 70 70 70 70 70 70 70 Feed [mm/rev] 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 0.103 0.103 0.103 0.137 0.137 0.137 0.164 0.164 0.164 DOC [mm] 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 0.5 0.75 1 CF [N] 102 376 650 263 537 811 391 665 939 32 241 515 128 402 676 256 530 804 167 106 380 6 267 541 121 395 663

6. SIMULATION RESULTS The effects of cutting parameters on the cutting force and surface roughness were evaluated by applying SENSITIVITY analysis in Nuero solutions. A single-factor experiment was conducted to explore the influence of feed on Surface Roughness and cutting speed on cutting force.

Fig 6

Fig 7

Fig 8

Fig 9

Fig 10

Fig 11

Figures presenting Sensitiveness results for Surface Roughness (6, 7, 8) and cutting force (9, 10, 11), showing the parameter with high influence on output.

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Fig 12

Fig 13

Fig 14

Fig 15

Fig 16

Fig 17

Figure 12, 13, 14, 15, 16, 17 are graphs of output with respect to high influence parameter (Speed for Surface Roughness and DOC in case of Cutting Force). Table 9 Percentage of influence of Each Parameter on Output Tool Parameter Cutting force Speed Uncoated tool Feed DOC Speed CVD tool Feed DOC Speed PVD tool Feed DOC 16.6 28.2 55.2 17.9 30.9 51.2 17.5 28.5 54 Surface Roughness 11.5 63.6 24.9 7.6 65.2 27.2 10.2 66.2 23.6

6.1 Conclusions on Effect of Parameters Feed has more effect on surface roughness than depth of cut and speed. During turning sometimes a higher value of roughness due to the presence of hard carbide particles present in the matrix has been identified. DOC has more effect on Cutting Force than feed and speed .Increasing the cutting speed to obtain smaller values of cutting forces is the most frequent method used in the literature. Also, higher feed rates were observed to be causing higher cutting forces.
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A direct relation was determined between the tested feed rates and average surface roughness and also between DOC and Cutting force. Surface roughness increases with an increase in the feed rate and depth of cut and a decrease in cutting speed.

7 .OPTIMAL PARAMETERS In order to obtain the optimal cutting conditions, the developed relation (mathematical form) has been feed to GA in MATLAB optimal Tool. Final Point at the left most corner of optim toll is the required optimum point. Table 10 Optimal Cutting Conditions for Lower SR Surface Roughness

Uncoated CVD PVD

SPEED FEED DOC 68.379 0.103 0.5 68.562 0.103 0.5 68.661 0.1031 0.502

Table 11 Optimal Cutting Conditions for minimal CF Cutting Forces

SPEED FEED DOC Uncoated 69.215 0.103 0.5 CVD 69.99 0.1042 0.5004 PVD 69.998 0.1033 0.5001 From the Tables 10 and 11 the Surface roughness and Cutting force has been found to be minimum at high speed, low feed and depth of cut, which agreements with metal cutting theory 8. CONFIRMATION TESTS Confirmation experiment was conducted using optimal conditions and the results are presented in table 12.

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Table 12 Machining Results at Optimum conditions Tool Value Cutting force Exp. Value Uncoated tool NN Value % Error Exp. Value CVD tool NN Value % Error Exp. Value PVD tool NN Value % Error 154 157.512 2.3 177 180.954 2.2 142 144.55 1.8 Surface Roughness 0.823 0.8362 1.7 0.76 0.779 2.6 0.786 0.802 2.1

9. CONCLUSIONS In this study, experimentation was done on Super alloy Inconel 718 to aquire training data NNs. Results from NN analysis are like this The optimum set of control factors indicates that at high cutting speed, and at low feed and depth of cut the cutting force & Surface Roughness is optimum in the selected range. For any required surface roughness, the developed model can predict the optimal values of speed, feed and depth of cut in any selected range. From the experimental results, tool with PVD coating have shown good performance than tool with CVD coating. Hence, PVD coated tools may be preferable for high speed dry turning of Inconel 718. REFERENCES 1. E.O. Ezugwu, Advances in the machining of nickel and titanium base super alloys, Keynote paper presented at the Japan Society for Precision Engineering Conference 2004, pp. 140. 2. Sims C. T, Stoloff N. S and Hagel W. C. (1987) Superalloys II- High temperature Materials for Aerospace and Industrial power New York: Willey. 3. Choudary I. A and M. A. EI-Baradie (1997) Machining nickel base super alloys: Inconel 718 Proceedings of Institution of Mechanical Engineers, part B 212, pp 195-206. 4. R.S. Pawade, S.S. Joshi, P.K. Brahmankar, Rahman, Some investigations of high-speed turned Inconel 718, in: V.S. Raja, Kuppan (Eds.), Proc.eedings of the of the 21st AIMTDR
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Conference, VIT, Vellore, 2004. 5. D. Dudzinski a, A. Devillez a, A. Moufki a, Larrouque`re b, V. Zerrouki b, J. Vigneau, ISGMP, University. 6. Zuperl U, Cus F, Mursec B, Ploj T (2004), A hybrid analytical neural network approach to the determination of optimal cutting conditions. J Mater Process Technol 157 158:8290 7. Yang WH, Tarng YS (1998) Design optimization of cutting parameters for turning operations based on the Taguchi method. J Mater Process Technol 84:1221299 8. E.O. Ezugwu, K.A. Olajire, J. Bonney, Modelling of tool wear based on component forces, Tribol. Lett. 11 (1) (2001). 9. E.O. Ezugwu, S.J. Arthur, E.L. Hines, Tool-wear prediction using artificial neural networks, J. Mater. Process. Technol. 49 (1995) 255264. 10. Ribeiro Filho, Jose L.; Treleaven, Philip C.; Alippi, Cesare: Genetic Algorithm Programming Environments. III: Computer (1994) June, p. 28 - 43. 11. http://www.neurosolutions.com/ 12 Valery Marinov, Manufacturing Technology, Kendall/Hunt Pub. Co, 2nd edition. 13. Phillip J. Ross, Taguchi Techniques for Quality Engineering, McGraw-Hill, 1996. 14. D. G.Thakur, B. Ramamoorthy, L. Vijayaraghavan, Effect of High Speed Cutting ParametersWC. 15. R. A. Smith, 2007 Jordan Journal of Mechanical and Industrial Engineering. - Volume 1, Number 1 (ISSN 1995-6665)

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