COMPARATIVE STUDY OF FORCE, STRAIN, AND VOLUME PERCENTAGE IN

HYDRAULIC IMPACT FORMING OF SUPERNI (INCONEL) 718

ABSTRACT:

Key words:

1. INTRODUCTION given in table 1.1. The Ni-based superalloy

SUPERNI / INCONEL 718 contains major constituent elements such as
Materials with distinctive metallurgical Nickel (Ni), Iron (Fe), Chromium (Cr),
properties – such as an alloy of titanium, Molybdenum (Mo), and Cobalt (Co) with
nickel, tool steel and other super alloys are some minor elements like Aluminum (Al),
primarily used for a specialized application Titanium (Ti), and so on. These alloying
requiring heat and corrosion resistance. These elements enhance the mechanical
materials exhibit several key characteristics characteristics. Where, Ni stabilizes alloy
such as excellent mechanical strength, structure and properties at elevated
resistance to creep at high temperature, high temperatures. Co, Mo, and W increase strength
work hardening, and corrosion resistance and at elevated temperature, Cr, Al, Si enhances
thus they are the first choice of aerospace, oxidation resistance and elevated temperature
submarine, gas turbine and nuclear industries. corrosion resistance, and Carbon (C) increases
However, these properties are generally creep strength. Nibased superalloys can also
associated with poor machinability. Hence, be broadly classified according to grade under
machining of such difficult-to-cut materials is the distinct groups.
quite crucial for the manufacturing sector.
Inconel 718 is a Ni-Cr based superalloy and SELECTION OF WORK MATERIAL
has been widely used in aviation, submarine, (Group A, Group B, Group C, and
nuclear, gas turbine, petroleum industries Group D) as shown in figure
because of its excellent mechanical properties
such as high strength, strong creep resistance,
superior wear resistance, resistance to
chemical degradation and low thermal
conductivity. However, the machining of
Inconel 718 using conventional machining
process like turning, grinding, broaching or
milling is very difficult because of its
workhardening nature, retention of high tensile
strength at elevated temperature and low
thermal conductivity. The chemical
composition of Superni 718 (sheet metal)
which is procured for research work from
Misha Dhatu Nigam Ltd., (MIDHANI) is as
 Fig: 1.6 Classification of Ni based
alloys
Group A contains more than 95% of Nickel.
These alloys have high toughness as well as
moderate mechanical strength. These alloys
are used for electronic parts in domestic
application and in corrosion resistance
applications, such as handling foods and
alkaline solutions. Group B contains Nickel
and Copper as major constituents. These alloys
have slightly lower toughness and higher
strength than Group A. These alloys are used
in a marine application, namely marine
fixtures, piping systems pumps, and valves.
Whereas Group C contains a large amount of
solution treated Ni-Cr and Ni-Cr-Fe elements.
These alloys are extensively used in aerospace
applications, namely for exhaust systems,
ducting, combustors, and thrust reversers.
Further, Group D contains primarily of age
hardenable alloys. These alloys can also be
subdivided into unaged and aged alloys. These
aged hardenable/ precipitate hardenable alloys
have high strength and hardness compared to
other groups. These alloys are used in high-
performance conditions, namely combustor
parts in jet engines, gas turbine engine
components, and nuclear reactors.
2. LITERATURE SURVEY
J. E Field et al. [1] the authors reported a
variety of techniques used to obtain the
mechanical properties of materials at higher
rate of strain (>=10s-1) are summarized. these
include drop weight machines, split
Hopkinson pressure bars, Taylor impact and
shock loading by plate impact. high speed
photography, particularly when used in
association with optical techniques, is a key
area and recent advances and applications to
studies of ballistic impact are discussed.
Sajun Prasad K et al. [2] In stress-strain
response with failure strains was evaluated by
uniaxial tensile tests in different orientations,
and two-stage work-hardening behaviour was
observed. A batch of mill-annealed IN718
material sheets of 1.2 mm thickness was
selected for present study. The microstructure
obtained by light microscopy, showing an
average grain size of 14 lm with a difference
in morphology in rolling (RD), transverse
(TD) and normal (ND) directions. Flat tensile
specimens were fabricated from the mill
annealed IN718 sheets by wire-cut electrical
discharge machining process as per
ASTME8M standard. Specimens were cut
along three orientations with respect to the
rolling direction (RD) of the sheets, viz.,
parallel (00), diagonal (450) and perpendicular
(900) directions. The mechanical properties of
these rolled sheets were almost similar along
different directions with the r values very
much close to 1.0. However, the rolled sheet
showed high texture with (110) plane normal
of most of the grains being parallel to the
normal direction of the sheet. Approximately
3.4% decrease in major strain was found due
to the bending correction in plane strain
condition.
D. Cesnik et al. [3] the aim of the research was
to define the time dependence of the force and
vertical movement of the punch at the same
time. Furthermore, the influences of different
heat treatment procedures on mechanical
properties of Inconel 718 alloy that are
reflected in the loading on the tool were
investigated. The temperature of solution
annealing affects the amount of phase which is
present in the nickel matrix and the
mechanical properties of Inconel 718.
Mechanical and microstructure properties of
sheet metal have an influence on the force in
fine-blanking. A line graph of force can be
divided into two parts. First with elastic
deformation of sheet metal, and the second
when the plastic deformation of sheet metal
begins and continues until the punch cuts
through the entire thickness.
Huang Y and Blackwell PL et al. [4]
Investigated the optimum force conditions for
Inconel 718 sheet by carrying experiments on
a sheet of 1.6mm thick and it is observed that
material was deforming on the border line
between regions 2 and 3 of the logarithmic
stress/strain curve.
3. DESIGN AND FABRICATION OF DIES
For the hydraulic impact forming of Superni
(Inconel) 718, three distinct dies have been
meticulously designed to cater to specific
geometrical profiles of the desired objects. The
first die, featuring a straight edge, is tailored
for a straightforward forming approach. Its
design is optimized to ensure uniform and
precise deformation during the hydraulic
impact process. The second die boasts an
inclined edge, introducing an additional
dimension to the forming dynamics. This
inclined edge design aims to impart specific
characteristics to the formed object, enhancing
its structural properties. The third die
incorporates a curved edge, introducing a
nuanced curvature to the forming process. This
design caters to objects requiring intricate
shapes and adds versatility to the hydraulic
impact forming technique.
In the current research work three types of dies
are prepared for experimentation of hydraulic
impact forming of Superni (Inconel) 718.
Design of dies are done based on the
geometrical profile of the object going to be
formed. The following cases are considered
for experimentation.
1. Hydraulic impact forming using straight
edge die
2. Hydraulic impact forming using inclined
edge die
3. Hydraulic impact forming using curve edge
die
Fig: 4.3. Forming die geometrical profiles: 1)
Straight 2) Inclined 3) Curve
3. EXPERIMENTATION
The experimental trails required is designed
using Taguchi DoE orthogonal arrays. The
number of input parameters identified for
experimentation are four and they are
Thickness of specimen, Height of the hammer,
Weight of the hammer, Viscosity of the Fluid
and the output responses considered are
Impact force, Deformation, Strain, Volume
fraction.
To conduct Taguchi Design of Experiments
(DoE) using orthogonal arrays for the
hydraulic impact forming of Superni (Inconel)
718, additional information is needed for the
impact force, strain, and volume fraction. The
following parameters should be considered for
each of the specified output responses:
In this study, we undertake a comprehensive
investigation into the hydraulic impact
forming of Superni (Inconel) 718, focusing on
the comparative analysis of force, strain, and
volume percentage. The experimental setup
incorporates specifically designed dies with
straight, inclined, and curved edges. Utilizing
Taguchi Design of Experiments (DoE)
methodology, we identify four primary input
parameters—Thickness of specimen, Height of
the hammer, Weight of the hammer, and
Viscosity of the Fluid. To enhance the depth of
understanding, additional parameters such as
Material Hardness, Hammer Velocity,
Forming Temperature, Hammer Shape, Fluid
Pressure, and Die Geometry are introduced for
the respective output responses. The
experimental design involves multiple trials
based on the Taguchi array, with precise data
collection of impact force, strain, and volume
percentage. Statistical tools, including analysis
of variance (ANOVA), are employed to
discern significant parameters and optimize
the process settings. Validation is ensured
through a comparative analysis with
theoretical predictions and existing literature.
4. RESULTS AND DISCUSSIONS
Output Straigh Inclined Curve
t edge Edge Edge
die die die
Force
Strain
% Volme
5. CONCLUSION
The weight of the hammer plays a
pivotal role in hydraulic impact
forming, showcasing substantial
 influence and higher variations at
lower levels. Force variation
decreases with increased geometric
complexity, from straight to curved
edges. The height of the hammer
intensifies force variation,
particularly at lower levels. Viscosity
mitigates force variation,
diminishing as geometric complexity
increases. Thickness significantly
impacts force, with the inclined edge
die showing higher variations
compared to the straight edge die.
These insights offer guidance for
optimizing the process across
various die geometries.

REFERENCES:

[1] Field J.E. Mechanical Properties of

Materials at Higher Rate of Strain
(>=10s-1) are summarized. Review
of Experimental Techniques for high
rate deformation And Shock Studies,
International Journal of Impact
Engineering, March, 2004.
[2] Sajun Prasada K, T. Kamala, S.K.
Panda S. Karb, S.V.S. Narayana
Murtyc and S.C Sharmac, Finite
Element Validation of Forming Limit
Diagram of In-718 Sheet Metal,
Sciencedirect, 2015.
[3] Cesnik D, J. Rozman, and M. Bizjak.
Influence of Sheet Metal on Fine-
Blanking Process. Materials and
Manufacturing Processes, 24: 832–
836, 2009.
[4] Huang Y & P. L. Blackwell,
Microstructure Development and
Super Plasticity in Inconel 718 Sheet,
Materials Science and Technology,
19 Jul 2013.