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Theoretical and experimental investigations of surface roughness, surface topography, and chip shape in ultrasonic vibration-assisted turning of Inconel 718

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Abstract

When processing difficult-to-cut materials, conventional turning (CT) typically suffers from the problems of large cutting force, difficult chip removal, and serious tool wear, resulting in deteriorated processing quality, reduced processing efficiency, and increased processing costs. In addition, special-purpose machine tools used for ultrasonic machining exhibit disadvantages, such as narrow application scope, high manufacturing cost, and poor universality; thus, they are not conducive to being popular in actual production and processing. Accordingly, this study analyzed the characteristics of ultrasonic wave, the mechanism of ultrasonic vibration-assisted turning (UAT), and the formation of a machined surface in UAT. Moreover, the machining system of UAT was established. This system applied an ultrasonic wave vibration device to an engine lathe to meet the requirements of vibration cutting in actual production. Simultaneously, Inconel 718, a typical and widely used difficult-to-cut material, was selected for the experimental study. The machining effect of UAT was analyzed in detail, including surface roughness, surface topography, and chip shape. Results indicated that ultrasonic amplitude, cutting speed, depth of cut, and feed rate exert considerable influences on the machining effect. UAT can achieve this effect, which is difficult to realize via CT, under the condition of a reasonable selection of technological parameters. This research can provide theoretical support and experimental basis for the development and practical application of UAT.

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Abbreviations

CT:

Conventional turning

UAT:

Ultrasonic vibration-assisted turning

CNC:

Numerically controlled

3D:

Three-dimensional

A :

Ultrasonic amplitude

Vc :

Cutting speed

ap :

Depth of cut

f :

Feed rate

Ra :

Surface roughness

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Acknowledgments

This work is supported by the Research Program of the Open Foundation of Jiangxi Province Engineering Research Center of New Energy Technology and Equipment, East China University of Technology (No. JXNE2019-03), the Science and Technology Research Project of Jiangxi Provincial Education Department, China (No. GJJ190370), the Natural Science Foundation of Jiangxi Province, China (No. 20202BAB204021), and the East China University of Technology Research Foundation for Advanced Talents (No. DHBK2016113).

Author information

Authors and Affiliations

  1. Jiangxi Province Engineering Research Center of New Energy Technology and Equipment, East China University of Technology, Nanchang, 330013, China

    Yingshuai Xu & Fanglei Fan

  2. School of Mechanical and Electronic Engineering, East China University of Technology, Nanchang, 330013, China

    Yingshuai Xu & Fanglei Fan

  3. School of Mechanical, Electronic, and Vehicle Engineering, Zhengzhou Institute of Technology, Zhengzhou, 450044, China

    Fei Gao

  4. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China

    Ping Zou

  5. School of Electromechanical Engineering, Beijing Information Science and Technology University, Beijing, 100192, China

    Qinjian Zhang

Authors
  1. Yingshuai Xu
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  2. Fei Gao
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  3. Ping Zou
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Corresponding author

Correspondence to Yingshuai Xu.

Additional information

Yingshuai Xu obtained his Ph.D. in Mechanical Manufacturing and Automation from Northeastern University, Shenyang, China in 2016. He is currently a lecturer at the School of Mechanical and Electronic Engineering, East China University of Technology, Nanchang. His research interests include ultrasonic vibration-assisted turning, milling and drilling of difficult-to-cut materials, cutting simulation, and faulty diagnosis.

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Xu, Y., Gao, F., Zou, P. et al. Theoretical and experimental investigations of surface roughness, surface topography, and chip shape in ultrasonic vibration-assisted turning of Inconel 718. J Mech Sci Technol 34, 3791–3806 (2020). https://doi.org/10.1007/s12206-020-0830-x

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  • DOI: https://doi.org/10.1007/s12206-020-0830-x

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