| Title |
Sustainable production of powder feedstock from machining waste using modulation-assisted drilling |
| ID_Doc |
14436 |
| Authors |
Singh, M; Dhiman, S; Singh, H; Rashid, RAR; Palanisamy, S |
| Title |
Sustainable production of powder feedstock from machining waste using modulation-assisted drilling |
| Year |
2024 |
| Published |
International Journal Of Advanced Manufacturing Technology, 133, 11-12 |
| DOI |
10.1007/s00170-024-14089-3 |
| Abstract |
High-quality metal and alloy powder feedstock for powder metallurgy (PM) and additive manufacturing (AM) is typically expensive due to stringent physical and chemical requirements. The increasing demand for such powders drives innovation toward more sustainable and cost-effective production methods. In this study, we demonstrate the generation of discrete machining chips (MCs) with controlled characteristics during modulation-assisted drilling of Inconel-718 nickel superalloy. To achieve this, a full factorial experimental design, varying modulation frequency (f(m)) and amplitude (2A) (two factors: f(m) and 2A, multi-level: 7 and 5, respectively) was used to define discrete and continuous cutting regimes. Furthermore, the effect of individual modulation (f(m) and 2A) and machining parameters (drill tool diameter, D, and feed rate, h) on the characteristics of MCs was investigated systematically. The findings reveal direct linear relationships between the investigated parameters, i.e., D, f(m), and 2A, on chip characteristics: length, width, and thickness, respectively. Specifically, the average chip length was 10-40% smaller than the length of each cutting edge of the drill tool; the average chip width reduces by 17 % when fm increases from 184 to 251 Hz. Similarly, the average chip thickness increases to 80% when 2A increases from 3.6 to 27.5 mu m, confirming the generation of MCs having controllable characteristics. As established using a comprehensive comparative analysis, generated MCs (size range: 100-1200 mu m) can be used as feedstock directly in press-and-sinter PM and solid-state friction-stir AM technologies. Additionally, the reusability of these MCs can be further enhanced by converting them into finer powder with a well-defined size distribution via ball milling (average particle size < 100 mu m having angular morphology, in the present case), promoting a circular economy by repurposing high-value industrial machining waste into useful products. |
| Author Keywords |
Modulation-assisted machining; Inconel-718; Machining waste; Recycling; Powder metallurgy; Additive manufacturing; Powder feedstock |
| Index Keywords |
Index Keywords |
| Document Type |
Other |
| Open Access |
Open Access |
| Source |
Science Citation Index Expanded (SCI-EXPANDED) |
| EID |
WOS:001263319300001 |
| WoS Category |
Automation & Control Systems; Engineering, Manufacturing |
| Research Area |
Automation & Control Systems; Engineering |
| PDF |
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