INVESTIGATION OF SURFACE CHARACTERISTICS IN PRECISION HOLE MACHINING OF INCONEL-625 USING ABRASIVE AQUA JET DRILLING

R. Vijaya Kumar, N. Srirangarajalu, M. Santhanakumar and R. Adalarasan
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R. Vijaya Kumar: Department of Mechanical Engineering, GRT Institute of Engineering and Technology, Tiruttani 631209, Tamilnadu, India
N. Srirangarajalu: ��Department of Production Technology, Madras Institute of Technology, Anna University, Chennai 600044, Tamilnadu, India
M. Santhanakumar: ��Department of Industrial Engineering, College of Engineering Guindy, Anna University, Chennai, Tamilnadu, India
R. Adalarasan: �Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai 602105, Tamilnadu, India

Surface Review and Letters (SRL), 2024, vol. 31, issue 08, 1-21

Abstract: Inconel-625 is a high-performance nickel-based superalloy which offers exceptional properties such as extensive resistance to corrosion, high strength-to-weight ratio, hardness, and impressive heat tolerance. Machining precise holes with required dimensional accuracy is challenging in Inconel-625 using conventional drilling processes. The investigation aims to improve the quality characteristics of hole machined on Inconel-625 by using the abrasive aqua jet drilling (AAJD) process. The influence of jet pressure (JP), table feed (TF), mass flow rate (MFR) and gap distance (GD) on the erosion rate (ER), surface roughness (Ra), circularity error (CIerror) and striation zone (SZN) are investigated. The weighted principal component analysis (WPCA)-based response surface methodology (WPC-RSM) is employed to analyze and optimize process parameters. The optimal parameter settings (JP-300 MPa, GD-1.5 mm, TF-64 mm/min, MFR-0.55 kg/min) are observed to produce substantial improvement in response. Comparing initial and optimal conditions, the surface roughness (Ra) is decreased by 10.15% from 3.25 μm to 2.92 μm. The CIerror and SZN are also reduced by 38.02% and 12.74%, respectively. The erosion rate (ER) is improved by 8.79% with the optimal settings. JP is found to be the most influential parameter, followed by MFR. Scanning electron microscopy (SEM) pictures and 3D roughness plots are used in the surface topography analysis.

Keywords: Inconel; Abrasive aqua jet drilling; 3D surface topography; WPCA; RSM (search for similar items in EconPapers)
Date: 2024
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DOI: 10.1142/S0218625X24500665

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