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Effects of Ultrasonics-Assisted Face Milling on Surface Integrity and Fatigue Life of Ni-Alloy 718

Abstract

This work investigates the effects of ultrasonic vibration-assisted milling on important aspects such us material surface integrity, tool wear, cutting forces and fatigue resistance. As an alternative to natural application of ultrasonic milling in brittle materials, in this study, ultrasonics have been applied to a difficult-to-cut material, Alloy 718, very common in high-temperature applications. Results show alterations in the sub-superficial part of the material which could influence fatigue resistance of the material, as it has been observed in a fatigue test campaign of specimens obtained with the application of ultrasonic milling in comparison with another batch obtained applying conventional milling. Tool wear pattern was found to be very similar for both milling technologies, concluding the study with the analysis of cutting forces, exhibiting certain improvement in case of the application of ultrasonic milling with a more stable evolution.

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Acknowledgments

The work was performed as a part of the HIMMOVAL (Grant Agreement Number: 620134) project within the CLEAN-SKY program, which relates to the SAGE2 project oriented to the geared open rotor development, enabling the delivery of the demonstrator part. We would also thank Iker Cerrillo for his great help and support during the project.

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Correspondence to Luis N. López de Lacalle.

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Suárez, A., Veiga, F., de Lacalle, L.N.L. et al. Effects of Ultrasonics-Assisted Face Milling on Surface Integrity and Fatigue Life of Ni-Alloy 718. J. of Materi Eng and Perform 25, 5076–5086 (2016). https://doi.org/10.1007/s11665-016-2343-6

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Keywords

  • Alloy 718
  • face milling
  • fatigue
  • surface integrity
  • ultrasonic-assisted milling