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<p>This research presents an investigation of the machining characteristics and surface integrity of Rene alloy, a difficult-to-cut super alloy. Primarily, Ultrasonic Machining (USM) is employed to evaluate material removal mechanisms. The results indicate that a high power rating of 450&#xa0;W combined with a 400-grit size maximized the material removal rate to 6.879&#xa0;mm³/min. In addition, SEM analysis revealed that impactful parameters initiated surface crack development. The Taguchi L9 orthogonal array was used to optimize the precision turning process with tungsten carbide tools. The minimization of surface roughness, tool tip temperature, and cutting force were the parameters analysed in the investigation. Atomic Force Microscope used to characterize the surface morphology. The results showed that high speeds and feed rates of the process results in a maximum roughness of 227&#xa0;nm because of increased tool-workpiece rubbing. However, the lower cutting speeds significantly enhance surface quality, achieving a mean roughness as low as 18.76&#xa0;nm. The present study developed an optimized condition for the machining performance that notably improves the surface roughness, tool tip temperature and cutting force. The systematic understanding of crack propagation behaviour studied under high USM conditions and suggest the usual condition for the optimal parameters selection. These findings help to improve the process stability, surface quality and efficiency of the machining process.</p>

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Multi-objective optimization of machining of Rene alloy: AFM and SEM insights into surface crack initiation

  • 期刊论文

  • 发表日期：

    2026年4月1日

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  • Rajiev R.,
  • Nithya K.,
  • Lakshmi M.,
  • Hemachandira V. S.,
  • Ramkumar R.,
  • Kandasamy T.

摘要

This research presents an investigation of the machining characteristics and surface integrity of Rene alloy, a difficult-to-cut super alloy. Primarily, Ultrasonic Machining (USM) is employed to evaluate material removal mechanisms. The results indicate that a high power rating of 450 W combined with a 400-grit size maximized the material removal rate to 6.879 mm³/min. In addition, SEM analysis revealed that impactful parameters initiated surface crack development. The Taguchi L9 orthogonal array was used to optimize the precision turning process with tungsten carbide tools. The minimization of surface roughness, tool tip temperature, and cutting force were the parameters analysed in the investigation. Atomic Force Microscope used to characterize the surface morphology. The results showed that high speeds and feed rates of the process results in a maximum roughness of 227 nm because of increased tool-workpiece rubbing. However, the lower cutting speeds significantly enhance surface quality, achieving a mean roughness as low as 18.76 nm. The present study developed an optimized condition for the machining performance that notably improves the surface roughness, tool tip temperature and cutting force. The systematic understanding of crack propagation behaviour studied under high USM conditions and suggest the usual condition for the optimal parameters selection. These findings help to improve the process stability, surface quality and efficiency of the machining process.