Ultrasonic Vibration Assisted Turning of Inconel 825: An Experimental Analysis

Sahoo, Ananda Kumar; Sahoo, Susanta Kumar; Pattanayak, Suvranshu; Moharana, Manoj Kumar

doi:10.1080/10426914.2023.2165675

Cited by 19 publications

(3 citation statements)

References 31 publications

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“…Here residuals are almost collinear with the linear fit line, indicating a good fitting of the developed model, accurate interval and p-values (Sahoo et al, 2023).…”

Section: Response Surface Methodologymentioning

confidence: 64%

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Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits

Pattanayak,

Sahoo,

Sahoo

et al. 2024

RPJ

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Purpose This study aims to demonstrate a modified wire arc additive manufacturing (AM) named non-transferring arc and wire AM (NTA-WAM). Here, the build plate has no electrical arc attachment, and the system’s arc is ignited between tungsten electrode and filler wire. Design/methodology/approach The effect of various deposition conditions (welding voltage, travel speed and wire feed speed [WFS]) on bead characteristics is studied through response surface methodology (RSM). Under optimum deposition condition, a single-bead and thin-layered part is fabricated and subjected to microstructural, tensile testing and X-ray diffraction study. Moreover, bulk texture analysis has been carried out to illustrate the effect of thermal cycles and tensile-induced deformations on fibre texture evolutions. Findings RSM illustrates WFS as a crucial deposition parameter that suitably monitors bead width, height, penetration depth, dilution, contact angle and microhardness. The ferritic (acicular and polygonal) and lath bainitic microstructure is transformed into ferrite and pearlitic micrographs with increasing deposition layers. It is attributed to a reduced cooling rate with increased depositions. Mechanical testing exhibits high tensile strength and ductility, which is primarily due to compressive residual stress and lattice strain development. In deposits, ϒ-fibre evolution is more resilient due to the continuous recrystallisation process after each successive deposition. Tensile-induced deformation mostly favours ζ and ε-fibre development due to high strain accumulations. Originality/value This modified electrode arrangement in NTA-WAM suitably reduces spatter and bead height deviation. Low penetration depth and dilution denote a reduction in heat input that enhances the cooling rate.

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“…Here residuals are almost collinear with the linear fit line, indicating a good fitting of the developed model, accurate interval and p-values (Sahoo et al, 2023).…”

Section: Response Surface Methodologymentioning

confidence: 64%

“…Step 4: To further depict the best fitting between actual and predicted responses, a probabilistic plot is generated (Figure 7). Here residuals are almost collinear with the linear fit line, indicating a good fitting of the developed model, accurate interval and p -values (Sahoo et al , 2023).…”

Section: Methodology and Experimental Proceduresmentioning

confidence: 76%

Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits

Pattanayak,

Sahoo,

Sahoo

et al. 2024

RPJ

Self Cite

View full text Add to dashboard Cite

show abstract

“…Furthermore, most studies on UVAT have primarily concentrated on ultrasonic devices and processes, with little attention paid to cutting tools. The direct application of high-frequency ultrasonic vibration and high cutting loads to the tool necessitates a high level of tool performance [52,65,66]. Therefore, the development of turning tools suitable for ultrasonic machining may become a prominent research direction in the future.…”

Section: Ultrasonic Vibration-assisted Turningmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Experimental Study of Multidimensional Ultrasonic Vibration-Assisted Milling of SiCp/Al Composites

Liang,

Sang,

et al. 2024

Int. J. Precis. Eng. Manuf.

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Ultrasonic Vibration Assisted Turning of Inconel 825: An Experimental Analysis

Cited by 19 publications

References 31 publications

Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits

Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Experimental Study of Multidimensional Ultrasonic Vibration-Assisted Milling of SiCp/Al Composites

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