Session: 03-01-01: Advanced Manufacturing in Aerospace Engineering

Paper Number: 166605

Micro-Hole Fabrication on Turbine Blade Made of Inconel 718 (Nickel-Based Super Alloy) Using Micro ECM Process Under Taguchi – DEAR Based Optimization 

Accurate and precise micro hole is an essential requirement for turbine blade applications in the present scenario. The turbine performance depends on turbine blade material and the process for making micro-hole with varying diameters of less than 500µm. The micro-holes in the turbine blades are mainly used for reducing the heat produced during its operation for improving efficiency and service life. Due to inherent properties of Inconel 718 alloy, it is being used in wide application of fuel injector nozzle for diesel engine and turbine blades in the field of aerospace and marine industries. Usually micro-holes produced on the fuel injection nozzle in compressive engines and turbine blades are machined using Electrical Discharge Machining and Laser Beam Machining process. But these processes have the following disadvantages i.e. lower material removal rate, rough surface finish, heat affected zone and high power consumption. Therefore, the Electrochemical Micro Machining (ECMM) is preferred as an alternate machining process for overcoming such problems. Since the electrochemical micromachining process involves various advantages such as no heat affected zone, no tool wear, stress and burr free operations compared to other micromachining process. Hence it is highly important to compute the optimum input parameters for enhancing the machining characteristics for micro-hole making using ECMM process. This will help to improve the surface integrity and functionality of the micro holed components. Many researchers reported the various machining techniques of inconel 718 alloy (Nickel-based super alloy) showed consistent improvement in its mechanical properties and performance measures [7-12]. However, the application of a material not only lies in the machining technique but also depends on the selection of manufacturing processes [13-15]. The problem for machining of inconel 718 alloy is hard to machine, because of the presence of twelve different composition of materials. There have been a number of studies in machining of nickel based super alloy material. However, only limited attempts were made to investigate the machinability of inconel 718 alloy using electrochemical micromachining process.

In this work an attempt will be carried out to investigate electrochemical micromachining process to analyze the influence of input process parameters on micro-hole machining characteristics of inconel alloy. The performance measures and surface topography acquired and input process parameters are also need to be observed and explained. The surface integrity and functionality of component are checked by performing mechanical test such as fatigue and creep test.  Apart from this work also helps to know about the effect of hybrid electrolyte and cryogenic treated tool electrode on machinability of inconel 718 alloy.  The proposed method can efficiently drill the proposed materials with no tool wear and heat affected zone.

Presenting Author: Muthuramalingam Thangaraj SRM Institute of Science and Technology

Presenting Author Biography: Muthuramalingam Thangaraj is currently working as Professor and Head at the Department of Mechatronics Engineering, SRM Institute of Science and Technology. His primary area of research interests are unconventional machining processes and Mechatronics. He has published many of his research papers in the area of EDM, ECM, AWJM, LBM processes, optimisation approaches and Manufacturing automation and control. He has been listed as Top 2% scientists in worldwide by Stanford University, USA.

Authors:

Muthuramalingam Thangaraj SRM Institute of Science and Technology
Ragavanantham Shanmugam Jacksonville State University
Monsuru Ramoni The University of Texas Rio Grande Valley
Geethapriyan Thangamani Politecnico di Torino