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Abstract
The relatively new technique of Fluidized Bed assisted Abrasive Jet Machining (FB-AJM) is
applied to finishing the inner surfaces of tubular Inconel 718 components. The effects of abrasive
size, jet pressure, and machining cycle were evaluated, and the behaviour of abrasive cutting edges
acting against the surface during the process to remove material is accounted for. The finished
surface was found to be highly dependent on jet pressure as it affects the abrasive contact against
the surface as well as the finishing force acting on the abrasive, on the abrasive grain size, which
controls the depth of cut, and on machining cycle, which controls the interaction time between the
abrasives and the surface being finished. By altering these conditions, this process achieves surface
roughness (Ra) as fine as 0.1 m and imparts minimal additional residual stress on the surface. This
study also reveals the mechanisms that determine the smoothing of the inner surface of Inconel 718
tubes and to improve the form accuracy, i.e. the internal roundness of the Inconel 718 tube.
Key words: Fluidized bed assisted abrasive finishing; Internal finishing; Inconel 718; Finishing
characteristics; Surface roughness; Roundness; Residual stress.
1. INTRODUCTION
Inconel 718 is a nickel-based super alloy well suited to applications requiring high strength over
temperature ranges from cryogenic up to 750 °C. Inconel 718 also exhibits excellent tensile and
impact strength. Common applications of Inconel 718 include jet engines, gas turbine operations,
heat exchangers, cryogenic storage tanks, as well as load-bearing components in which the sliding
surfaces between inner and outer races of bearings require highly smoothed surfaces and form
accuracy to reduce wear and so extend effective life [1].
Obtaining high quality internal finishing on Inconel 718 components can be extremely
complicated [2]. In fact, conventional machining techniques used for iron based alloys can make the
Inconel 718 alloy work-harden during machining [2]. Moreover, Inconel 718 has higher strength
and "gumminess" not typical of steels. Heavy duty machining equipment and tooling should be
used to minimize chatter and work-hardening of the alloy before cutting. In turning in particular,
high-speed steel tooling with positive rake angle should be used for interrupted cuts and for smooth
finishing to close tolerance [3]. However, even if all precautions are taken during Inconel 718
machining, whenever workpieces characterized by complex shapes or a high length L to diameter D
ratio must be machined, conventional solutions are a critical and time-consuming stage of the
manufacturing process [4]. Both the machining and the finishing stage of the manufacturing
process can be compromised by severe tool vibration, large bending, and tool failure [4], therefore
the demand for alternative techniques has been increasing [5].
Several advanced machining solutions able to process complex shaped components are detailed in
the scientific literature [4-5]. Mechanisms regulating material removal and surface finishing are
modeled and energy sources, transfer media, and cutting tools used in each process have been
comprehensively described [6]. As a result, several analyses classifying the most suitable machining
technologies according to workpiece material, geometry, and end use are found in the specialized
literature [7-10]. When accurate finishing of high strength materials or of components with complex
configurations is required, several limitations affect all machining technologies, including the most
advanced. For example, etching processes are commonly used for internal finishing, but they have
drawbacks associated with the control of the surface quality and the treatment of chemical waste
[7]. It is therefore desirable to find an alternative internal finishing process to replace chemical
finishing processes. Techniques based on abrasive flows and jets such as abrasive jet machining
(AJM) [8], abrasive flow machining (AFM) [9], and abrasive magnetic flow machining (AMFM)
[10]) at best only produce reasonable results. At the same time, of all the techniques based on
abrasive flows and jets, AJM is commonly considered the most competitive as it involves shorter
start-up times as well as lower investment and running costs [4]. Even though AJM involves the
least investment and the most economical operating costs, and is not affected by any drawbacks
associated with the use of solid tools (vibrations, inflexions, or failures), and benefits from a high
degree of operational flexibility and shorter processing time, it does suffer from several limitations.
These are generally caused by the unpredictable hydrodynamic properties of the abrasive jet,
making this process unsuitable for most tubular shaped parts. Precision and repeatable machining
can be virtually impossible using AJM [11-12], and operating problems can arise including
chocking regimes, significant nozzle wear, contamination of the atmosphere from dispersed fines,
as well as continuous demand for abrasive replacement [13-14].
As an alternative to AJM, Barletta et al. tested the relatively novel hybrid technology of Fluidized
Bed assisted Abrasive Jet Machining (FB-AJM) using tubular workpieces (L/D≤20) made from
stainless steel [15] and high strength aluminum [16] alloys. This technology uses the fluidized bed
hydrodynamic to improve the abrasive feeding system, the uniformity of abrasive distribution
through the workpiece, and the recovery and self-regeneration of abrasive during machining.
Consequently, precision, uniformity, and above all, repeatable machining as well as accurate
surface finishing can be achieved even on the inner surfaces of tubular parts [15-16]. Nevertheless,
several concerns regarding the possibility of extending FB-AJM to components made from
specialized metal superalloys in order to produce fine surface finishes, improving their form
accuracy, and imparting minimal residual stresses on them, still remain unanswered.
This is the context in which the evaluation of how the progression of material removal and the
modification of surface texture during fluidized bed assisted abrasive finishing process of tubular
components made from high yield strength metal superalloys (i.e. Inconel 718 SPF) took place.
Design of experiment (DOE) techniques were used to evaluate the influence of operational
variables (i.e. abrasive mesh size, machining cycle, and jet pressure) on mass removal rate and
surface roughness. The finished surface was found to be highly dependent on three factors: firstly,
jet pressure, which affects the abrasive contact against the surface as well as the finishing force
acting on the abrasive; secondly, on the abrasive grain size, which controls the depth of cut; and
thirdly, on machining cycle, which controls the interaction time between the abrasives and the
surface being finished. The best way of choosing the operational parameters is by experimentally
analyzing these three factors to deduce them.
The macroscopic morphological modification of machined surfaces according to mesh size of
abrasive media was investigated using high resolution 3D profilometry. Therefore, tests on the
circumferential uniformity, precision, and repeatability of FB-AJM on the workpiece inner surfaces
could be carried out. In addition to this, leading process mechanisms, which concurrently determine
material removal and the establishment of a smoother finish, could be interpreted in the light of the
microscopic modification of the machined surfaces, assessed by FE-SEM analysis. Finally, the
improvements in form accuracy and the minimal occurrence of residual stresses on workpieces after
finishing were carefully checked, therefore providing definitive assessment of how suitable
fluidized bed assisted technology is for the finishing of complex shaped Inconel 718 components.
2. METHODS
Figure 1. The fluidized bed assisted abrasive jet machining (FB-AJM) system.
Figure 11. Circumferential uniformity of surface finishing after FB-AJM according to abrasive mesh size
Figure 12. 3D maps of inner surfaces of Inconel 718 tubular workpieces after form suppression: (a) untreated; (b)
24 mesh size; (c) 46 mesh size; (d) 80 mesh size; (e) 180 mesh size; (f) 280 mesh size; (g) 400 mesh size
Figure 13. Tubular workpiece cilindricity before and after FB-AJM machining according to abrasive mesh size
Figure 14. FFT analysis of 3D maps of the inner surfaces of Inconel 718 tubular workpieces after form suppression
and zoom on first 20 Hz: (a) untreated; (b) 24 mesh size; (c) 46 mesh size; (d) 80 mesh size; (e) 180 mesh size; (f) 280
mesh size; (g) 400 mesh size
Figure 15. Residual stresses of tubular workpieces before and after FB-AJM machining according to abrasive
mesh size