Novel use of ultrasonic-assisted turning in conjunction with cryogenic and lubrication techniques to analyze the machinability of Inconel 718

Abstract

Industries have been pursuing a competent machining system that meets the necessity of sustainability without deteriorating tool wear or final part quality of components made from difficult-to-cut material ‘Inconel 718’. In this regard, a novel study, applying ultrasonic vibration along with lubrication (MQL) and cooling (LCO2) is proposed to enhance the machinability of Inconel 718. The purpose of this work is to examine the machinability of Inconel 718 in conventional and ultrasonic-assisted turning (UAT) under dry, wet, MQL, and LCO2. The experiments are performed on an in-house developed UAT setup, keeping all the machining parameters constant. The LCO2 considerably reduces edge chipping, nose wear, adhesion, and abrasion wear in both the processes. Quantitatively, the conventional turning under LCO2 reduces the flank wear by 32–60 %, power consumption by 4–41 %, and power consumption by 5–31 % compared to dry, wet, and MQL strategies. Similarly, the UAT under LCO2 reduces the flank wear by 32–53 %, power consumption by 11–40 % and power consumption by 5–31 % compared to dry, wet, and MQL strategies. The UAT reduces the surface roughness and power consumption compared to conventional turning when used under MQL and LCO2. The LCO2 in conjunction with ultrasonic vibration significantly reduces specific cutting energy and tool wear without compromising the surface quality. Moreover, the combination also helps in enhancing the chip breakability and reducing the strain localization. Ultimately, the UAT, along with LCO2 promotes sustainability in the machining of Inconel 718.