Investigation of machining rate and roughness for rotary ultrasonic drilling of Inconel 718 alloy with slotted diamond metal bonded tool

Abstract

Super alloy has extensive engineering applications in nuclear industries owing to its outstanding performance characteristics at elevated temperature. More than 30% of consumption in nuclear industries is super alloy. A number of holes are required to be drilled into super alloys for their final stage assembly. During conventional machining process, excessive heat is generated, which is the cause of heat treated zone that further affect the life and performance of the product. To overcome this difficulty, a rotary ultrasonic machining method came into existence to machine super alloys by hybrid cutting action (vibratory and rotary) of diamond impregnated core drill. This study focuses on the machining characteristics of super alloy by RUM process. The empirical modelling of process parameters of RUM is carried out for super alloy (Inconel 718) using an experimental design approach called response surface methodology. Material removal efficiency of RUM and surface topography of the machined material are studied. The results reported that for quality and productivity aspect, the feed rate in RUM is found a most critical factor.Reference to this paper should be made as follows: Popli, D. and Gupta, M. (2018) 'Investigation of machining rate and roughness for rotary ultrasonic drilling of Inconel 718 alloy with slotted diamond metal bonded tool', Int. NIT is an institution of national importance. She has more than 25 years of experience in teaching and research. Her current areas of research include machine vision, image processing, optimisation, and modelling.

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

“…Feed speed is the most critical factor affecting processing quality and production rate [35]. Lower cutting speed and feed per tooth have the best effect on burr suppression.…”