An Experimental Investigation into the Enhancement of Surface Quality of Inconel 718 Through Axial Ultrasonic Vibration-Assisted Grinding in Dry and MQL Environments
Ultrasonic vibration-assisted grinding (UVAG) has proven to be beneficial for grinding difficult-to-machine materials. This work attempts to enhance the grinding performance of Inconel 718 through a comprehensive study of UVAG characteristics. Grinding experiments were performed in both dry and Mini...
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2024-11-01
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| author | Sreethul Das Pandivelan Chinnaiyan Joel Jayaseelan Jeyapandiarajan Paulchamy Andre Batako Ashwath Pazhani |
| author_facet | Sreethul Das Pandivelan Chinnaiyan Joel Jayaseelan Jeyapandiarajan Paulchamy Andre Batako Ashwath Pazhani |
| author_sort | Sreethul Das |
| collection | DOAJ |
| description | Ultrasonic vibration-assisted grinding (UVAG) has proven to be beneficial for grinding difficult-to-machine materials. This work attempts to enhance the grinding performance of Inconel 718 through a comprehensive study of UVAG characteristics. Grinding experiments were performed in both dry and Minimum Quantity Lubrication (MQL) environments, and assessment of the grinding forces, specific energy, residual stress, and surface topography was done. A substantial reduction of both surface roughness and grinding force components was observed in UVAG compared to conventional grinding (CG). Utilizing UVAG with MQL at the maximum vibration amplitude led to a 64% reduction in tangential grinding force and a 51% decrease in roughness parameter, <i>R<sub>a</sub></i>, when compared to CG conducted in a dry environment. The high-frequency indentations of the abrasives in UVAG generated compressive residual stresses on the ground surface. Surface parameters pointed to uniform texture and SEM images showed widening of abrasive grain tracks on the workpiece surface during UVAG. The utilization of UVAG under MQL produced a synergistic impact and resulted in the lowest grinding forces, specific energy, and optimal surface quality among all the grinding conditions investigated. Overall analysis of the results indicated that the axial configuration of the vibration set-up is favorable for UVAG, and the high-frequency periodic separation-cutting characteristic of the process improves lubricating efficiency and grinding performance. |
| format | Article |
| id | doaj-art-3e47050e4dca46658b9c85f17c12dab5 |
| institution | DOAJ |
| issn | 2504-4494 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | MDPI AG |
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| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-3e47050e4dca46658b9c85f17c12dab52025-08-20T02:56:55ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942024-11-018625510.3390/jmmp8060255An Experimental Investigation into the Enhancement of Surface Quality of Inconel 718 Through Axial Ultrasonic Vibration-Assisted Grinding in Dry and MQL EnvironmentsSreethul Das0Pandivelan Chinnaiyan1Joel Jayaseelan2Jeyapandiarajan Paulchamy3Andre Batako4Ashwath Pazhani5School of Mechanical Engineering, Vellore Institute of Technology, Vellore 632014, IndiaSchool of Mechanical Engineering, Vellore Institute of Technology, Vellore 632014, IndiaSchool of Mechanical Engineering, Vellore Institute of Technology, Vellore 632014, IndiaSchool of Mechanical Engineering, Vellore Institute of Technology, Vellore 632014, IndiaGeneral Engineering Research Institute, Liverpool John Moores University, Liverpool L3 5UX, UKFaculty of Engineering, Environment and Computing, Coventry University, Coventry CV1 5FB, UKUltrasonic vibration-assisted grinding (UVAG) has proven to be beneficial for grinding difficult-to-machine materials. This work attempts to enhance the grinding performance of Inconel 718 through a comprehensive study of UVAG characteristics. Grinding experiments were performed in both dry and Minimum Quantity Lubrication (MQL) environments, and assessment of the grinding forces, specific energy, residual stress, and surface topography was done. A substantial reduction of both surface roughness and grinding force components was observed in UVAG compared to conventional grinding (CG). Utilizing UVAG with MQL at the maximum vibration amplitude led to a 64% reduction in tangential grinding force and a 51% decrease in roughness parameter, <i>R<sub>a</sub></i>, when compared to CG conducted in a dry environment. The high-frequency indentations of the abrasives in UVAG generated compressive residual stresses on the ground surface. Surface parameters pointed to uniform texture and SEM images showed widening of abrasive grain tracks on the workpiece surface during UVAG. The utilization of UVAG under MQL produced a synergistic impact and resulted in the lowest grinding forces, specific energy, and optimal surface quality among all the grinding conditions investigated. Overall analysis of the results indicated that the axial configuration of the vibration set-up is favorable for UVAG, and the high-frequency periodic separation-cutting characteristic of the process improves lubricating efficiency and grinding performance.https://www.mdpi.com/2504-4494/8/6/255hybrid machiningaxial UVAGInconel 718surface textureresidual stressMQL |
| spellingShingle | Sreethul Das Pandivelan Chinnaiyan Joel Jayaseelan Jeyapandiarajan Paulchamy Andre Batako Ashwath Pazhani An Experimental Investigation into the Enhancement of Surface Quality of Inconel 718 Through Axial Ultrasonic Vibration-Assisted Grinding in Dry and MQL Environments Journal of Manufacturing and Materials Processing hybrid machining axial UVAG Inconel 718 surface texture residual stress MQL |
| title | An Experimental Investigation into the Enhancement of Surface Quality of Inconel 718 Through Axial Ultrasonic Vibration-Assisted Grinding in Dry and MQL Environments |
| title_full | An Experimental Investigation into the Enhancement of Surface Quality of Inconel 718 Through Axial Ultrasonic Vibration-Assisted Grinding in Dry and MQL Environments |
| title_fullStr | An Experimental Investigation into the Enhancement of Surface Quality of Inconel 718 Through Axial Ultrasonic Vibration-Assisted Grinding in Dry and MQL Environments |
| title_full_unstemmed | An Experimental Investigation into the Enhancement of Surface Quality of Inconel 718 Through Axial Ultrasonic Vibration-Assisted Grinding in Dry and MQL Environments |
| title_short | An Experimental Investigation into the Enhancement of Surface Quality of Inconel 718 Through Axial Ultrasonic Vibration-Assisted Grinding in Dry and MQL Environments |
| title_sort | experimental investigation into the enhancement of surface quality of inconel 718 through axial ultrasonic vibration assisted grinding in dry and mql environments |
| topic | hybrid machining axial UVAG Inconel 718 surface texture residual stress MQL |
| url | https://www.mdpi.com/2504-4494/8/6/255 |
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