Performance Optimization of Novel Laser Hybrid Ultrasonic Vibration Assisted Micro Milling for Inconel 718

Area of Science:

• Advanced Manufacturing
• Materials Science
• Mechanical Engineering

Background:

• Miniaturization in aerospace, biomedical, and microelectronics necessitates advanced manufacturing techniques.
• Superalloys like Inconel 718 present significant machining challenges due to their properties.
• Hybrid machining offers a way to combine processes for improved results.

Purpose of the Study:

• To investigate the machinability of Inconel 718 using a novel laser hybrid ultrasonic vibration-assisted micro-milling (L-UVAMM) process.
• To analyze the effects of cutting parameters and tool coatings on surface roughness, tool wear, and burr formation.
• To identify optimal machining conditions for Inconel 718 using L-UVAMM.

Main Methods:

• Experimental research employing a Taguchi L-16 orthogonal array to design experiments.
• Utilizing fiber laser for slot preparation followed by micro-milling with uncoated and coated tools.
• Applying Analysis of Variance (ANOVA) and Grey Relational Analysis (GRA) for parameter significance and optimization.

Main Results:

• Tool type was identified as the most significant factor (45.76% contribution) affecting machining responses.
• Uncoated tools showed minimal wear; TiSiN coating reduced burr height; TiAlN coating improved surface roughness and reduced burr width.
• Optimized conditions using Response Surface Method led to average reductions of 43.96% in surface roughness, 27.18% in tool wear, and 19.65% in burr formation.

Conclusions:

• L-UVAMM is a viable hybrid process for machining Inconel 718.
• Tool coating selection is critical for balancing surface finish, tool wear, and burr formation.
• The study provides optimized parameters for enhanced micro-milling of Inconel 718.