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<p>Miniaturization in advanced manufacturing has increased the demand for high-precision machining of difficult-to-cut superalloys such as Inconel 718, an alloy widely used in aerospace, medical, and microelectronics applications. However, achieving improved surface integrity and tool performance during micro-machining remains a significant challenge due to severe tool wear and burr formation. In this study, the micro-machinability of Inconel 718 was systematically investigated using ultrasonic vibration-assisted micro-milling (UVAMM) with uncoated and three coated micro-cutting tools. A Taguchi L16 orthogonal experimental design was employed to evaluate the effects of cutting speed, feed rate, depth of cut, tool coating type, and vibration amplitude on surface roughness, tool wear, and burr formation. Furthermore, Statistical analyses based on Analysis of Variance (ANOVA) and Grey Relational Analysis (GRA) were conducted to identify significant parameters to determine optimal machining conditions. The results revealed that uncoated tools minimized tool wear and burr generation, whereas nACo-coated tools achieved superior surface finish. ANOVA of the developed regression model identified tool type as the most influential factor, which contributed 23.41% to total variability. Further optimization using Response Surface Methodology (RSM) resulted in average reductions of 22.85%, 14.87%, and 19.76% in surface roughness, tool wear, and burr formation, respectively, demonstrating the effectiveness of UVAMM for enhanced micro-machining performance of Inconel 718.</p>

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Ultrasonic vibration assisted micro milling for Inconel 718 with coated micro end mills

  • 期刊论文

  • 发表日期：

    2026年6月24日

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  • Ahmad Waqar Tehami,
  • Muhammad Rizwan ul Haq,
  • Syed Hussain Imran Jaffery,
  • Muhammad Salman Khan,
  • Yasir Ali

摘要

Miniaturization in advanced manufacturing has increased the demand for high-precision machining of difficult-to-cut superalloys such as Inconel 718, an alloy widely used in aerospace, medical, and microelectronics applications. However, achieving improved surface integrity and tool performance during micro-machining remains a significant challenge due to severe tool wear and burr formation. In this study, the micro-machinability of Inconel 718 was systematically investigated using ultrasonic vibration-assisted micro-milling (UVAMM) with uncoated and three coated micro-cutting tools. A Taguchi L16 orthogonal experimental design was employed to evaluate the effects of cutting speed, feed rate, depth of cut, tool coating type, and vibration amplitude on surface roughness, tool wear, and burr formation. Furthermore, Statistical analyses based on Analysis of Variance (ANOVA) and Grey Relational Analysis (GRA) were conducted to identify significant parameters to determine optimal machining conditions. The results revealed that uncoated tools minimized tool wear and burr generation, whereas nACo-coated tools achieved superior surface finish. ANOVA of the developed regression model identified tool type as the most influential factor, which contributed 23.41% to total variability. Further optimization using Response Surface Methodology (RSM) resulted in average reductions of 22.85%, 14.87%, and 19.76% in surface roughness, tool wear, and burr formation, respectively, demonstrating the effectiveness of UVAMM for enhanced micro-machining performance of Inconel 718.