Ultrasonic Vibration Assisted Turning of Inconel 825: An Experimental Analysis

Abstract

In this experimental analysis, ultrasonic-vibration-assisted-turning (UVAT) is introduced to machine Inconel 825 using TiAlN coated WC insert. Different turning conditions (varying ultrasonic power intensity, feed rate and cutting speed) are generated using response surface methodology. Turning performances like cutting force (Fc), temperature (T) and surface roughness (Ra) were analyzed through invasive weed optimization to distinct the critical turning parameter. Fc, T and Ra have been decreased by 34.99%, 20.61% and 24.73% in UVAT than CT, due to intermittent motion of the cutting tool. It minimizes the contact time between tool and workpiece, helps in better heat dissipation during machining and relieves excessive stress developed at tooltip that enhances tool life. TiAlN coating further curtailed the friction between tool-workpiece interfaces, improving surface quality, reducing stress, temperature and wear on the tool. Tool wear and chip morphology is analyzed with SCM, and XRD is utilized to identify crystallographic analysis and residual stress..