Machining of aluminium 7075-T6 alloy under dry environment using DLC coated tool Kshitij Pandey, Nidhi Mishra International Journal of Machining and Machinability of Materials, 2024 Excellent strength-to-weight fraction of aluminium alloys (mainly series 2XXX, 6XXX and 7XXX) makes them perfect for use in aircraft industries. Among the aluminium alloys, 7075 is used for manufacturing of shafts, gears and machine fittings. The present study include the comparative analysis of DLC coated tungsten carbide (WC) insert and uncoated WC insert during the machining of AA 7075-T6 under dry environment. T6 stands for a specific heat treatment provided to 7075 alloy resulting in enhanced mechanical properties of 7075-T6 alloy compared to conventional 7075 alloy. The performance of both inserts is compared in respect of cutting force, tool-tip temperature and wear morphology of tool.
Dry machining of inconel 825 superalloys: Performance of tool inserts (Carbide, Cermet, and SiAlON) Kshitij Pandey, Saurav Datta International Journal of Manufacturing Materials and Mechanical Engineering, 2021 The present work investigates application feasibility of PVD TiN/TiCN/TiN coated cermet and CVD Al2O3/TiCN coated SiAlON for dry machining of Inconel 825 superalloy. Machining performance is interpreted through cutting force magnitude, tool-tip temperature, and mechanisms of tool wear. Results are compared to that of CVD multi-layer TiN/TiCN/Al2O3/TiN coated WC-Co tool. It is evidenced that SiAlON tool generates lower cutting force but experiences higher tool-tip temperature than other two counterparts. Apart from abrasion and adhesion, carbide tool witnesses coating peeling and ploughing. In contrast, SiAlON tool suffers from inexorable chipping and notching. Wear pattern of cermet tool seems less severe than carbide and SiAlON. Chip's underside surface morphology appears relatively better in case of cermet tool.
Machinability of Inconel 825 superalloy under dry cutting environment with application of uncoated WC-Co tool Kshitij Pandey, Lebbar Md. Abdul Rahman, Saurav Datta Materials Today Proceedings, 2020 Nickel-based superalloy Inconel 825 is applied in aerospace, defense, and automotive industries. It possesses high corrosion resistance, and strength (hot strength) even at extreme temperature conditions. However, strong work-hardening tendency, high chemical reactivity (towards tool material), and poor thermal conductivity are dominant reasons which make this alloy to be categorized as ‘difficult-to-cut’. Therefore, machining this alloy through conventional method is indeed a challenge for the manufacturing industries. In the current work, machinability of Inconel 825 is studied under dry environment using uncoated tungsten carbide tool. Cutting force magnitude, tool-tip temperature generated, and morphology of tool wear are studied herein.
Deposition of hBN+Cu layer through electrical discharge process using green compact electrode Rashi Tyagi, Kshitij Pandey, Alok Kumar Das, Amitava Mandal Materials and Manufacturing Processes, 2019 In the current investigation, solid-lubricant surfaces were prepared onto the mild steel work piece by means of electrical discharge coating process in electrical discharge machine (EDM). Hexagonal boron nitride (hBN) and copper (Cu) powder-based green compact electrodes, prepared in hot mounting press were used as an EDM tool. The loosely bonded material particles from the compact tool were transported to the mild steel surface. With the change of process parameters (powder mixture ratio, duty factor, and peak current), the variation in surface morphology, micro-hardness and tribological properties of hBN-Cu coating layer has been discussed. Following the investigation, field emission scanning electron microscopic (FESEM) images of coating indicated fewer gaps and pores for the powder lubricant mixing ratio of hBN: Cu/50:50, peak current value of 10 A and duty factor value of 70%. X-ray diffraction plot composed of prominent peaks of BN, Cu, along with Fe2O3 (intermetallic compound). Micro-hardness value of lubricant surfaces drastically reduced to the minimum of 75.76 HV (coating layer) from 180 HV (substrate). Moreover, pin on disk tribological test indicated the lubrication effect of hBN particles by revealing a major drop in wear value from 95.75 µm (work piece) to 1.52 µm (coating) and friction coefficient from 0.9 (work piece) to 0.1 (coating).
