Theoretical and experimental investigations of surface roughness, surface topography, and chip shape in ultrasonic vibra
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DOI 10.1007/s12206-020-0830-x
Journal of Mechanical Science and Technology 34 (9) 2020 Original Article DOI 10.1007/s12206-020-0830-x Keywords: · Ultrasonic vibration · Turning · Technological parameter · Surface roughness · Surface topography · Chip shape · Inconel 718
Theoretical and experimental investigations of surface roughness, surface topography, and chip shape in ultrasonic vibration-assisted turning of Inconel 718 Yingshuai Xu1,2, Fei Gao3, Ping Zou4, Qinjian Zhang5 and Fanglei Fan1,2
Correspondence to: Yingshuai Xu [email protected]
Citation: Xu, Y. S., Gao, F., Zou, P., Zhang, Q. J., Fan, F. L. (2020). Theoretical and experimental investigations of surface roughness, surface topography, and chip shape in ultrasonic vibration-assisted turning of Inconel 718. Journal of Mechanical Science and Technology 34 (9) (2020) 3791~3806. http://doi.org/10.1007/s12206-020-0830-x
Received March 2nd, 2020 Revised
July 4th, 2020
Accepted July 15th, 2020 † Recommended by Editor Hyung Wook Park
1
Jiangxi Province Engineering Research Center of New Energy Technology and Equipment, East China 2 University of Technology, Nanchang 330013, China, School of Mechanical and Electronic Engineering, 3 East China University of Technology, Nanchang 330013, China, School of Mechanical, Electronic, and 4 Vehicle Engineering, Zhengzhou Institute of Technology, Zhengzhou 450044, China, School of Me5 chanical Engineering and Automation, Northeastern University, Shenyang 110819, China, School of Electromechanical Engineering, Beijing Information Science and Technology University, Beijing 100192, China
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 par
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