Skip to main content
SpringerLink
Log in

Enhancement of Machinability Study in Longitudinal Ultrasonic Vibration-assisted Milling Inconel 718 Using High-frequency-vibration Spindle

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Longitudinal ultrasonic vibration-assisted machining (LUVAM) is a machining technique that offers several benefits such as low cutting force, good surface quality, and prolonged tool life. A new set of LUVAM spindle with high-frequency vibrations was designed to enhance the efficiency of LUVAM and the critical cutting speed of "tool-workpiece separation." The spindle's stepped axial vibration transducer is designed analytically, and its amplitude is amplified. The spindle's performance was assessed by measuring resonant frequencies and amplitudes of tungsten carbide and high speed steel tool at varying lengths. Experimental results showed that the transducer's maximum resonance frequency was around 33.52 kHz, and its maximum amplitude was approximately 24.03 μm. The maximum spindle speed exceeded 20,000 rpm, and the runout error was low during high-speed operations. Additionally, Inconel 718 was machined with the new spindle, and the experimental cutting force, machining temperature, surface morphology, chip, and surface integrity were analyzed under different machining parameters. The test results showed that LUVAM could successfully reduce cutting force and temperature while improving surface integrity when separation conditions are met. Compared to conventional machining, LUVAM reduced cutting force and average cutting temperature by up to 23.3% and 19.8%, respectively. The new spindle design provides a new approach for high-quality, efficient, and eco-friendly machining of difficult-to-cut materials.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22

Similar content being viewed by others

Data availability

Data and material availability are available upon request from the authors.

Code availability

The code is available from the authors upon request.

References

  1. Sonar T, Balasubramanian V, Malarvizhi S, Venkateswaran T, Sivakumar D (2021) An overview on welding of Inconel 718 alloy - Effect of welding processes on microstructural evolution and mechanical properties of joints. Mater Charact 174:110997. https://doi.org/10.1016/j.matchar.2021.110997

    Article  Google Scholar 

  2. Rahman M, Seah WKH, Teo TT (1997) The machinability of inconel 718. J Mater Process Technol 63(1–3):199–204. https://doi.org/10.1016/s0924-0136(96)02624-6

    Article  Google Scholar 

  3. Jafarian F, Imaz Ciaran M, Umbrello D, Arrazola PJ, Filice L, Amirabadi H (2014) Finite element simulation of machining Inconel 718 alloy including microstructure changes. Int J Mech Sci 88:110–121. https://doi.org/10.1016/j.ijmecsci.2014.08.007

    Article  Google Scholar 

  4. Teti R (2002) Machining of Composite Materials. CIRP Ann 51(2):611–634. https://doi.org/10.1016/s0007-8506(07)61703-x

    Article  Google Scholar 

  5. Yang Z, Zhu L, Zhang G, Ni C, Lin B (2020) Review of ultrasonic vibration-assisted machining in advanced materials. Int J Mach Tools Manuf 103594. https://doi.org/10.1016/j.ijmachtools.2020.103594

  6. Brehl DE, Dow TA (2008) Review of vibration-assisted machining. Precis Eng 32(3):153–172. https://doi.org/10.1016/j.precisioneng.2007.08.003

    Article  Google Scholar 

  7. Chen W, Huo D, Shi Y, Hale JM (2018) State-of-the-art review on vibration-assisted milling: principle, system design, and application. Int J Adv Manuf Technol 97(5–8):2033–2049. https://doi.org/10.1007/s00170-018-2073-z

    Article  Google Scholar 

  8. Ning F, Cong W (2020) Ultrasonic vibration-assisted (UV-A) manufacturing processes: State of the art and future perspectives. J Manuf Process 51:174–190. https://doi.org/10.1016/j.jmapro.2020.01.028

    Article  Google Scholar 

  9. Liu X, Wu D, Zhang J et al (2019) Analysis of surface texturing in radial ultrasonic vibration-assisted turning. J Mater Process Technol 267:186–195. https://doi.org/10.1016/j.jmatprotec.2018.12.021

    Article  Google Scholar 

  10. Yan L, Zhang X, Li H, Zhang Q (2022) Machinability improvement in three-dimensional (3D) ultrasonic vibration assisted diamond wire sawing of SiC. Ceram Int 48:6. https://doi.org/10.1016/j.ceramint.2021.12.006

    Article  Google Scholar 

  11. Yang T, Fang X, Hang Y, Xu Z, Zeng Y (2021) Workpiece vibration in feed direction assisted electrochemical cutting using tube electrode with inclined holes. Int J Adv Manuf Technol 116(7–8):2651–2660. https://doi.org/10.1007/s00170-021-07556-8

    Article  Google Scholar 

  12. Luo H, Wang Y, Zhang P (2020) Effect of cutting and vibration parameters on the cutting performance of 7075-T651 aluminum alloy by ultrasonic vibration. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-020-05098-z

  13. Liu Y, Liu Z, Wang X, Huang T (2020) Experimental study on tool wear in ultrasonic vibration–assisted milling of C/SiC composites. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-020-05060-z

  14. Choi Y-J, Park K-H, Hong Y-H, Kim K-T, Lee S-W, Choi H-Z (2013) Effect of ultrasonic vibration in grinding; horn design and experiment. Int J Precis Eng Manuf 14(11):1873–1879. https://doi.org/10.1007/s12541-013-0253-1

    Article  Google Scholar 

  15. Wu Y, Yokoyama S, Sato T, Lin W, Tachibana T (2009) Development of a new rotary ultrasonic spindle for precision ultrasonically assisted grinding. Int J Mach Tools Manuf 49(12–13):933–938. https://doi.org/10.1016/j.ijmachtools.2009.06.012

    Article  Google Scholar 

  16. Greco S, Kirsch B and Aurich J C (2018) Vibration-assisted air bearing spindle for micro machining - development of a magnetic field controlled ultrasonic actuator. Proceedings of the 18th euspen International Conference 141–142

  17. Wu C, Chen S, Cheng K, Ding H, Xiao C (2018) Innovative design and analysis of a longitudinal-torsional transducer with the shared node plane applied for ultrasonic assisted milling. Proc Inst Mech Eng C J Mech Eng Sci. https://doi.org/10.1177/0954406218797962

  18. Gao J, Caliskan H, Altintas Y (2019) Sensorless control of a three-degree-of-freedom ultrasonic vibration tool holder. Precis Eng. https://doi.org/10.1016/j.precisioneng.2019.05.005

  19. Haili J, Chen W, Fan K, Hua Z (2020) Design and simulation analysis of ultrasonic extrusion transducer. 2020 3rd World Conference on Mechanical Engineering and Intelligent Manufacturing (WCMEIM) 802–805. https://doi.org/10.1109/WCMEIM52463.2020.00171

  20. Feng Y, Hsu F-C, Lu Y-T, Lin Y-F, Lin C-T, Lin C-F, Lu Y-C, Liang SY (2020) Temperature prediction of ultrasonic vibration-assisted milling. Ultrasonics p. 106212. https://doi.org/10.1016/j.ultras.2020.106212

  21. Feng Y, Hsu F-C, Lu Y-T, Lin Y-F, Lin C-T, Lin C-F, Lu Y-C, Liang SY (2020) Force prediction in ultrasonic vibration-assisted milling. Mach Sci Technol 25. https://doi.org/10.1080/10910344.2020.1815048

  22. Feng Y, Hsu F-C, Lu Y-T, Lin Y-F, Lin C-T, Lin C-F, Lu Y-C, Lu X, Liang SY (2020) Surface roughness prediction in ultrasonic vibration-assisted milling. J Adv Mech Des Syst Manuf 14(4):JAMDSM0063. https://doi.org/10.1299/jamdsm.2020jamdsm0063

  23. Amin SG, Ahmed MHM, Youssef HA (1995) Computer-aided design of acoustic horns for ultrasonic machining using finite-element analysis. Journal of Materials Processing Tech 55(3-4):254–260. https://doi.org/10.1016/0924-0136(95)02015-2

  24. Kumar Patel L, Kumar Singh A, Sharma V, Kala P (2020) Analysis of a hybrid ultrasonic horn profile using finite element analysis. Mater Today: Proc. https://doi.org/10.1016/j.matpr.2020.08.465

  25. Mughal KH, Qureshi MAM, Raza SF (2021) Novel ultrasonic horn design for machining advanced brittle composites: A step forward towards green and sustainable manufacturing. Environ Technol Innov 23:101652. https://doi.org/10.1016/j.eti.2021.101652

  26. Chen W, Huo D, Hale J, Ding H (2018) Kinematics and tool-workpiece separation analysis of vibration assisted milling. Int J Mech Sci 136:169–178. https://doi.org/10.1016/j.ijmecsci.2017.12.037

    Article  Google Scholar 

  27. Pengfei D, La H, Qiu X, Chen W, Deng J, Liu Y, Zhang J (2022) Development of a high-precision piezoelectric ultrasonic milling tool using longitudinal-bending hybrid transducer. Int J Mech Sci. https://doi.org/10.1016/j.ijmecsci.2022.107239

  28. Shokrani, Dhokia V, Newman ST, Imani-Asrai R (2012) An Initial Study of the Effect of Using Liquid Nitrogen Coolant on the Surface Roughness of Inconel 718 Nickel-Based Alloy in CNC Milling. Procedia CIRP 3:121–125. https://doi.org/10.1016/j.procir.2012.07.022

    Article  Google Scholar 

  29. Touazine H, Jahazi M, Bocher P (2016) Accurate determination of damaged subsurface layers in machined Inconel 718. Int J Adv Manuf Technol 88(9–12):3419–3427. https://doi.org/10.1007/s00170-016-9039-9

    Article  Google Scholar 

  30. Xu M, Li C, Kurniawan R et al (2022) Ultrasonic and electrical discharge–assisted milling of the Ti-6Al-4 V alloy. Int J Adv Manuf Technol 122:1897–1917. https://doi.org/10.1007/s00170-022-10010-y

    Article  Google Scholar 

  31. Dongliang X (2012) Study on tribological properties of surfaces machined by ultrasonic vibration assisted milling. Shandong University, Shandong

    Google Scholar 

  32. Jie L, Zhu S-s, Xiao-lan X, Xin D (2021) Cutting Performance of AlCrSiN Coated Tool in Dry Turning Ti-6Al-4V Titanium Alloy. Journal of Guangdong University of Technology 38(02):99–106. https://doi.org/10.3390/mi11020137

    Article  Google Scholar 

  33. Baoqi C, Zhaoxi Y, Xiaobing C, Ji-an D (2022) Surface feature and material removal in ultrasonic vibration-assisted slot-milling of Ti–6Al–4 V titanium alloy. Int J Adv Manuf Technol 122:2235–2251. https://doi.org/10.1007/s00170-022-09970-y

    Article  Google Scholar 

  34. Guo S, Du W, Jiang Q, Dong Z, Zhang B (2021) Surface Integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting. Chinese J Mech Eng 34(1). https://doi.org/10.1186/s10033-021-00586-z

  35. Liang X, Liu Z, Chen L, Hao G, Wang B, Cai Y, Song Q (2020) Tool wear induced modifications of plastic flow and deformed material depth in new generated surfaces during turning Ti-6Al-4V. J Mater Res Technol 9(5):10782–10795. https://doi.org/10.1016/j.jmrt.2020.07.093

    Article  Google Scholar 

Download references

Funding

This research was supported by the National Research Foundation of Korea (NRF) grant funded by the Korean government (MSIT) (2020R1A2B5B02001755). Also, this research was funded by the Ministry of Science and ICT (MSIT) through the Korea Electrotechnology Research Institute's (KERI) primary research program through the National Research Council of Science and Technology (NST) in 2023. (No. 23A01021).

Author information

Authors and Affiliations

  1. Room for Precision Machining Laboratory, Yeungnam University, Gyeongsan-si, Republic of Korea

    Moran Xu, Shuo Chen, Rendi Kurniawan, Ye In Kwak, Saood Ali, Min Ki Choo & Tae Jo Ko

  2. High Efficiency and Precision Machining of Difficult-to-Cut Materials in Hunan Province, Hunan University of Science and Technology, Xiangtan, China

    Moran Xu & Changping Li

  3. Electric Machines and Drives Research Center, Korea Electrotechnology Research Institute, 12 Jeongiui-gil, Seongsan-gu, Chanwon-si, Gyeongsangnam-do, 51543, Republic of Korea

    Pil-Wan Han

Authors
  1. Moran Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shuo Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Rendi Kurniawan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Changping Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Ye In Kwak
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Saood Ali
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Min Ki Choo
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Pil-Wan Han
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Tae Jo Ko
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Moran Xu: Conceptualization, Investigation, Experiments, Software, Writing- Preparation of the first draft, Visualization. Shuo Chen: Formal analysis, Investigation, Visualization. Rendi Kurniawan: Supervision, Validation. Changping Li: Conceptualization, Methodology, Resources. Ye In Kwak: Data curation. Saood Ali: Visualization. Min Ki Choo: Data curation. Pil-Wan Han: Software. Tae Jo Ko: Conceptualization, Resources, Visualization, Supervision, Project administration, Funding acquisition

Corresponding authors

Correspondence to Rendi Kurniawan, Changping Li or Tae Jo Ko.

Ethics declarations

Consent to participate

This is not applicable.

Ethics approval

This is not applicable.

Consent for publication

This is not applicable.

Conflict of interest

The authors declare no competing interests. The authorship and funding have been declared properly.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Xu, M., Chen, S., Kurniawan, R. et al. Enhancement of Machinability Study in Longitudinal Ultrasonic Vibration-assisted Milling Inconel 718 Using High-frequency-vibration Spindle. Int J Adv Manuf Technol 126, 3523–3542 (2023). https://doi.org/10.1007/s00170-023-11319-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11319-y

Keywords

Search

Navigation