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<p>A nickel-chromium-based superalloy, Inconel 718 is widely utilized in aviation and power generation sectors because of its outstanding mechanical strength and thermal stability. However, its inherent characteristics such as poor thermal conductivity and high hardness make it challenging for machining by conventional methods. This study investigates the application of vibration-assisted turning (VAT) to enhance the machinability of Inconel 718 by controlled ultrasonic vibrations in tangential direction of cutting tool. A fully coupled three-dimensional finite element (FE) model is developed and experimentally validated. The model integrates ultrasonic effects through advanced constitutive behavior and is capable of simultaneously predicting the cutting force, temperature and circumferential residual stress. The study also explores the influence of critical VAT process parameter including vibration amplitude, frequency, cutting speed, feed rate and depth of cut within a unified simulation framework. The findings provide critical insights into the thermo-mechanical behavior of Inconel 718 in VAT, showing that cutting force and temperature reduction up to 8% and 12%, respectively, by providing vibration with 20&#xa0;kHz of frequency and 20&#xa0;μm of amplitude compared to conventional turning (CT). The FE model is established as a reliable tool for predicting machining performance, with potential applications in optimizing VAT for other materials that are challenging to machine.</p>

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Constitutive Thermo-Mechanical Model for Parametric Analysis in Vibration-Assisted Turning of Inconel 718

  • 期刊论文

  • 发表日期：

    2025年9月25日

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  • Banoth Srinu,
  • Vamsi Krishna Pasam,
  • Venu Gopal Anne

摘要

A nickel-chromium-based superalloy, Inconel 718 is widely utilized in aviation and power generation sectors because of its outstanding mechanical strength and thermal stability. However, its inherent characteristics such as poor thermal conductivity and high hardness make it challenging for machining by conventional methods. This study investigates the application of vibration-assisted turning (VAT) to enhance the machinability of Inconel 718 by controlled ultrasonic vibrations in tangential direction of cutting tool. A fully coupled three-dimensional finite element (FE) model is developed and experimentally validated. The model integrates ultrasonic effects through advanced constitutive behavior and is capable of simultaneously predicting the cutting force, temperature and circumferential residual stress. The study also explores the influence of critical VAT process parameter including vibration amplitude, frequency, cutting speed, feed rate and depth of cut within a unified simulation framework. The findings provide critical insights into the thermo-mechanical behavior of Inconel 718 in VAT, showing that cutting force and temperature reduction up to 8% and 12%, respectively, by providing vibration with 20 kHz of frequency and 20 μm of amplitude compared to conventional turning (CT). The FE model is established as a reliable tool for predicting machining performance, with potential applications in optimizing VAT for other materials that are challenging to machine.