Cutting Performance of a Longitudinal and Torsional Ultrasonic Vibration Tool in Milling of Inconel 718
Source abstract
Abstract
Inconel 718 has excellent thermal and chemical properties and is widely used in the manufacture of aerospace parts; however, there are some problems in the machining of Inconel 718, such as a large milling force, serious tool wear, and poor surface quality. In this research, a type of longitudinal–torsional ultrasonic milling (LTUM) tool is designed based on theoretical computations and FEM simulation analysis. To verify the design rationality of the developed LTUM tool, milling experiments are performed. It is verified that the LTUM tool can realize an elliptical vibration path at the tool tip. The resonance frequency of the tool is 21.32 kHz, the longitudinal amplitude is 6.8 µm, and the torsional amplitude is 1.4 µm. In the milling of Inconel 718, the experimental data of LTUM are compared with those of conventional milling (CM). The comparative experiments show that the LTUM tool can effectively lessen the milling force and tool wear in the milling of Inconel 718, improve the surface quality, inhibit the generation of burrs, and improve the chip breaking ability. The application potential of the LTUM tool in high-performance milling of Inconel 718 parts is proven.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Advanced machining processes and optimization · Advanced Machining and Optimization Techniques · Advanced Surface Polishing Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
Shandong Institute of Mechanical Design and Research, Jinan 250031, China
Funding
National Natural Science Foundation of China · Natural Science Foundation of Shandong Province · Talent Research Project of Qilu University of Technology (Shandong Academy of Sciences) · Basic Research Project of Science, Education and Industry Integration Pilot Project of Qilu University of Technology (Shandong Academy of Sciences)
References (31)
Show source-provided references
1. Cutting performance and tool wear of SiAlON and TiC-whisker-reinforced Si3N4 ceramic tools in side milling Inconel 71810.1016/j.ceramint.2021.10.084 ↗
2. A feeding-directional cutting load model for end surface grinding of CFRP composites using rotary ultrasonic machining with elliptical ultrasonic vibration10.1016/j.ijmachtools.2020.103540 ↗
3. System design and experimental research on ultrasonic assisted elliptical vibration grinding of Nano-ZrO2 ceramics10.1016/j.ceramint.2019.08.273 ↗
4. Effect of 3D elliptical ultrasonic assisted boring on surface integrity10.1016/j.measurement.2020.108008 ↗
5. Ultrasonic rolling strengthening effect on the bending fatigue behavior of 12Cr2Ni4A steel gears10.1016/j.engfracmech.2022.109024 ↗
6. Improved fretting fatigue mechanism of surface-strengthened Ti-6Al-4V alloy induced by ultrasonic surface rolling process10.1016/j.ijfatigue.2023.107567 ↗
7. Surface and subsurface analysis of TC18 titanium alloy subject to longitudinal-torsional ultrasonic vibration-assisted end milling10.1016/j.jallcom.2022.167259 ↗
8. Ultrasonic vibrating system design and tool analysis10.1016/S1003-6326(10)60275-0 ↗
9. Study on the simulativeand experiment of ultrasonic-assisted vibration drilling of Ti6Al4V10.1088/1742-6596/2242/1/012011 ↗
10. Rotary ultrasonic machining of ceramic matrix composites: Feasibility study and designed experiments10.1016/j.ijmachtools.2005.01.034 ↗
11. Design and development of an ultrasonic vibration assisted turning system for machining bioabsorbable magnesium alloys10.1016/j.procir.2018.09.026 ↗
12. Optimizing amplitude to improve machined surface quality in longitudinal ultrasonic vibration-assisted side milling 2.5 DC/SiC composites10.1016/j.compstruct.2022.115963 ↗
13. An experimental study on surface quality of Al6061-T6 in ultrasonic vibration-assisted milling with minimum quantity lubrication10.1016/j.procir.2022.04.071 ↗
14. Surface quality and milling force of SiCp/Al ceramic for ultrasonic vibration-assisted milling10.1016/j.ceramint.2022.07.331 ↗
15. Material removal and surface generation in longitudinal-torsional ultrasonic assisted milling10.1016/j.ijmecsci.2022.107375 ↗
16. Tool wear and its effect on the surface integrity and fatigue behavior in high-speed ultrasonic peening milling of Inconel 71810.1016/j.triboint.2022.108070 ↗
17. Analytical modeling of tool-workpiece contact rate and experimental study in ultrasonic vibration-assisted milling of Ti–6Al–4V10.1016/j.ijmecsci.2018.04.037 ↗
18. Geometrical texture and surface integrity in helical milling and ultrasonic vibration helical milling of Ti-6Al-4V alloy10.1016/j.jmatprotec.2019.116494 ↗
19. Defect suppression and grain refinement during ultrasonic vibration-assisted side milling of GH4169 superalloy10.1016/j.jmapro.2022.11.011 ↗
20. Long, Z.L., Liu, Y.C., Zhang, Z.Y., Liu, S., and Zhou, J.J. (2017, January 18–20). Design for torsional transducer in ultrasonic machining based on equivalent circuit. Proceedings of the 2017 IEEE International Conference on Information and Automation (ICIA), Macao, China.10.1109/ICInfA.2017.8079040 ↗
21. Study on surface quality of BK7 optical glass by longitudinal torsional composite ultrasonic vibration milling10.4028/www.scientific.net/MSF.984.51 ↗
22. Theoretical investigation of machining-induced residual stresses in longitudinal torsional ultrasonic–assisted milling10.1007/s00170-020-05495-4 ↗
23. Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity10.1016/j.ultras.2015.02.006 ↗
24. Controllable fabrication of microstructures on the metallic surface using oblique rotary ultrasonic milling10.1016/j.ijmecsci.2022.107805 ↗
25. Development of a high-precision piezoelectric ultrasonic milling tool using longitudinal-bending hybrid transducer10.1016/j.ijmecsci.2022.107239 ↗
26. Design of a Bézier-profile horn for high displacement amplification10.1016/j.ultras.2010.07.004 ↗
27. Development and optimization of ultrasonic elliptical vibration cutting device based on single excitation10.1115/1.4049965 ↗
28. Novel ultrasonic horn design for machining advanced brittle composites: A step forward towards green and sustainable manufacturing10.1016/j.eti.2021.101652 ↗
29. Cutting performance and surface integrity for rotary ultrasonic elliptical milling of Inconel 718 with the ball end milling cutter10.1016/j.jmatprotec.2023.118094 ↗
30. Cutting force model of longitudinal-torsional ultrasonic-assisted milling Ti-6Al-4V based on tool flank wear10.1016/j.jmatprotec.2021.117042 ↗
31. A study ofthe surface microstructure and tool wear of titanium alloys after ultrasonic longitudinal-torsional milling10.1016/j.jmapro.2020.01.040 ↗