Comparative Analysis of Vibration Axis Effect Ultrasonic Machining Inconel 718 #WorldResearchAwards

Introduction

Inconel 718 is a nickel-based superalloy extensively used in aerospace and other critical engineering applications due to its excellent high-temperature strength, creep resistance, and corrosion resistance. Despite these advantages, its poor machinability poses serious challenges, including excessive cutting forces, rapid tool wear, and inferior surface quality when using conventional machining. Ultrasonic Vibration-Assisted Machining (UVAM) has gained significant attention as an advanced manufacturing approach capable of addressing these issues by introducing controlled high-frequency vibrations into the cutting process. This research focuses on understanding how different UVAM vibration axes influence the machining performance of Inconel 718.

Challenges in conventional machining of inconel 718

The machining of Inconel 718 using conventional methods is hindered by its high hardness, strong work-hardening behavior, and low thermal conductivity. These properties lead to severe heat concentration at the cutting zone, increased tool–workpiece adhesion, unstable chip formation, and poor surface integrity. As a result, achieving high productivity and surface quality simultaneously becomes extremely difficult, highlighting the need for innovative machining strategies such as UVAM.

Ultrasonic vibration-assisted machining principles

UVAM operates by superimposing low-amplitude, high-frequency vibrations onto the cutting motion, altering the tool–workpiece interaction mechanism. Depending on the vibration direction, UVAM can induce intermittent cutting, reduce friction, and improve chip breakability. In this study, three UVAM modes—longitudinal (Z-UVAM), feed-directional (X-UVAM), and multi-axial (XZ-UVAM)—were evaluated to understand their distinct effects on machining dynamics and surface generation.

Comparative effects of vibration axis on cutting performance

The results demonstrate that vibration direction plays a crucial role in machining efficiency. While both Z-UVAM and X-UVAM showed improvements over conventional machining, XZ-UVAM delivered the most significant benefits. The combined vibration along feed and longitudinal directions promoted intermittent cutting, leading to a substantial reduction in cutting forces—up to 43% compared with conventional machining—thereby enhancing process stability and tool life.

Surface integrity and subsurface characteristics

Surface quality analysis revealed that XZ-UVAM achieved up to 37% reduction in areal surface roughness, producing more uniform surface topographies with reduced peak-to-valley variations. Additionally, the surface hammering effect induced by ultrasonic vibrations increased subsurface microhardness. This enhancement in near-surface mechanical properties is expected to positively influence fatigue performance, which is critical for aerospace components.

Implications for sustainable and high-quality manufacturing

Beyond force and surface improvements, XZ-UVAM significantly minimized burr formation, contributing to better dimensional accuracy and reduced post-processing requirements. These outcomes position multi-axial UVAM as a promising, sustainable, and high-efficiency machining technique for difficult-to-cut superalloys like Inconel 718, with strong potential for adoption in advanced manufacturing and aerospace industries.

Global Particle Physics Excellence Awards


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