Machining of Hastelloy-X Based on Finite Element Modelling

Abstract:

Nickel-based alloys provide high corrosion resistance and high-temperature strength but these alloys possess poor machinability. Hastelloy-X is a nickel based alloy that has been used for high temperature use. There are many studies about finite element modeling of aerospace alloys but studies in literature with Hastelloy-X are limited. In the present work, machining characteristics of Hastelloy-X were investigated and a numerical model was developed for the turning operation of Hastelloy-X. Two input parameters (cutting speed and feed rate) were variated in the operations and the results were evaluated considering process outputs such as cutting forces, cutting temperature, effective stresses and chip morphology. Based on the verification of the numerical model using experimental results, presented material model is appropriate for the turning operation of Hastelloy-X at low and medium cutting speed machining conditions.

• Periodical: Advanced Engineering Forum (Volume 30)
• Pages: 1-7
• DOI: https://doi.org/10.4028/www.scientific.net/AEF.30.1
• Online since: November 2018
• Authors: Fatih Hayati Çakır, Mehmet Alper Sofuoğlu, Selim Gürgen*
• Keywords: Cutting Force, Cutting Temperature, Hastelloy-X, Numerical Simulation, Turning

References

[1] Akıncıoğlu, S, Gökkaya, H and Uygur, İ., The effects of cryogenic-treated carbide tools on tool wear and surface roughness of turning of Hastelloy C22 based on Taguchi method,, Int. J. Adv. Manuf. Technol., vol. 82, no. 1–4, p.303–314, (2016).

DOI: 10.1007/s00170-015-7356-z

[2] Ulutan, D. and Ozel, T., Machining induced surface integrity in titanium and nickel alloys: A review,, Int. J. Mach. Tools Manuf., vol. 51, no 3, p.250–280, (2011).

DOI: 10.1016/j.ijmachtools.2010.11.003

[3] Choudhury, I., and El-Baradie, M., Machinability of nickel-base super alloys: a general review,, J. Mater. Process. Technol., vol. 77, no 1–3, p.278–284, (1998).

DOI: 10.1016/s0924-0136(97)00429-9

[4] Altin, A.,Optimization of the turning parameters for the cutting forces in the Hastelloy X superalloy based on the Taguchi method,, Mater. Tehnol., vol. 48, no 2, p.249–254, (2014).

[5] Kadirgama, K., Abou-El-Hossein, K.A., Noor M.M., Sharma, K.V., and Mohammad, B., Tool life and wear mechanism when machining Hastelloy C-22HS,, Wear, vol. 270, no 3–4, p.258–268, (2011).

DOI: 10.1016/j.wear.2010.10.067

[6] Kadirgama, K., Noor, M.M., Abou-El-Hossein, K.A., Mohammad, B., and Habeeb, H.H., Aspects of Wear Mechanisms of Carbide Tools when Machine Hastelloy C-22HS,, Adv. Mater. Res., vol. 83–86, p.295–302, (2009).

DOI: 10.4028/www.scientific.net/amr.83-86.295

[7] Kadirgama, K., Rahman, M., Mohamed, B., Bakar, R.and Ismail, A., Development of temperature statistical model when machining of aerospace alloy materials,, Therm. Sci.,vol. 18, p.269–282, (2014).

DOI: 10.2298/tsci120203112k

[8] Kadirgama, K., Abou-El-Hossein, K. A., Mohammad, B. and Habeeb, H., Statistical model to determine surface roughness when milling hastelloy C-22HS,, J. Mech. Sci. Technol., vol. 21, no 10, p.1651–1655, (2007).

DOI: 10.1007/bf03177389

[9] Khidhir, B. A., and Mohamed, B., Study of cutting speed on surface roughness and chip formation when machining nickel-based alloy,, J. Mech. Sci. Technol., vol. 24, no 5, p.1053–1059, (2010).

DOI: 10.1007/s12206-010-0319-2

[10] Khidhir, B.A. and Mohamed, B., Analyzing the effect of cutting parameters on surface roughness and tool wear when machining nickel based hastelloy – 276,, IOP Conf. Ser. Mater. Sci. Eng., vol. 17, no. 12043, pp.1-10, (2011).

DOI: 10.1088/1757-899x/17/1/012043

[11] Razak, N. H., Rahman, M. M. and Kadirgama, K., Response Surface Design Model to Predict Surface Roughness when Machining Hastelloy C-2000 using Uncoated Carbide Insert,, IOP Conf. Ser. Mater. Sci. Eng., vol. 36, no 12022, pp.1-9, (2012).

DOI: 10.1088/1757-899x/36/1/012022

[12] Chennamsetty, A.R.K., LeBlanc, J., Abotula, S., Parrikar, P. N., and Shukla, A., Dynamic response of Hastelloy® X plates under oblique shocks: Experimental and numerical studies,, Int. J. Impact Eng., vol. 92, p.75–88, (2016).

DOI: 10.1016/j.ijimpeng.2016.03.006

[13] Swaminathan, B.,Abuzaid, W., Sehitoglu, H., and Lambros, J., Investigation using digital image correlation of Portevin-Le Chatelier Effect in Hastelloy X under thermo-mechanical loading,, Int. J. Plast., vol. 64, p.177–192,(2015).

DOI: 10.1016/j.ijplas.2014.09.001

[14] Aghaie-Khafri, M., and Golarzi, N., Forming behavior and workability of Hastelloy X superalloy during hot deformation,, Mater. Sci. Eng. A, vol. 486, no 1–2, p.641–647, (2008).

DOI: 10.1016/j.msea.2007.11.059

[15] Abotula, S., Heeder, N., Chona, R., and Shukla, A., Dynamic Thermo-mechanical Response of Hastelloy X to Shock Wave Loading,, Exp. Mech., vol. 54, no 2, p.279–291, (2014).

DOI: 10.1007/s11340-013-9796-4

[16] Abotula, S., Shukla, A., and Chona, R., Dynamic constitutive behavior of Hastelloy X under thermo-mechanical loads,, J. Mater. Sci., vol. 46, no 14, p.4971–4979, (2011).

DOI: 10.1007/s10853-011-5414-y

[17] Li, R., Shih, A.J., Finite element modeling of 3D turning of titanium,, International Journal of Advanced Manufacturing Technology, p.2511–2516, (2005).