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Performance Study of Ultrasonic-Assisted Micro-Electrical Discharge Machining of Inconel 718 Superalloy Using Rotary Tool Electrode

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Abstract

Inconel 718 is extremely difficult-to-machine by conventional drilling due to its low thermal conductivity and work hardening nature. Electrical discharge machining (EDM) is a well-known process to machine any hard and brittle electrically conductive material. But, in micro-EDM drilling of Inconel 718, ejection of debris from machining zone is a challenging task for conventional flushing methods due to micro-size holes and low heat conduction efficiency of this material. In this study, a novel approach has been used to improve the flushing conditions in micro-EDM drilling of Inconel 718, in which ultrasonic vibration is given to workpiece and rotation is given to tool electrode. The simultaneous effect of tool rotation and workpiece vibration has been studied on material removal rate (MRR), hole taper (Ta) and tool wear rate (TWR) due to variation of gap current (Ig), pulse on-time (Ton), pulse off-time (Toff), tool RPM (N) and ultrasonic power (UP) using one parameter at a time methodology. Experiments have also been performed without rotation of tool and without vibrating workpiece and compared with the results obtained in the condition of rotating tool and vibrating workpiece, respectively. The experimental results reveal that MRR is higher for both the high ultrasonic power and high tool RPM. But, TWR and Ta are lower for high ultrasonic power, and higher at high tool RPM. Besides it, the quality of microholes has been found to be improved with rotating tool and vibrating workpiece when the surface of microholes was observed using scanning electron microscopy.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Hamirpur, Hamirpur, 177005, Himachal Pradesh, India

    Param Singh

  2. Department of Mechanical Engineering, Motilal Nehru National Institute of Technology Allahabad, Prayagraj, 211004, Uttar Pradesh, India

    Vinod Yadava & Audhesh Narayan

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  1. Param Singh
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Correspondence to Param Singh.

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Singh, P., Yadava, V. & Narayan, A. Performance Study of Ultrasonic-Assisted Micro-Electrical Discharge Machining of Inconel 718 Superalloy Using Rotary Tool Electrode. J. Inst. Eng. India Ser. C 104, 149–162 (2023). https://doi.org/10.1007/s40032-022-00892-y

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