Application of Taguchi method in the optimization of cutting parameters for turning operations

Application of Taguchi method in the optimization of cutting

parameters for turning operations
Guey-Jiuh Tzou 1*, Ding-Yeng Chen2, Chun-Yao Hsu1
1
Department of Mechanical Engineering, Lunghwa University of Science and
Technology, Taiwan, (R.O.C.)
2
Department of Mechanical Engineering, Hwa Hsia institute of Technology,
Taiwan (R.O.C.)

ABSTRACT
Nickel-base superalloy Inconel 718 is a high-strength, thermal-resistant. Because of its
excellent mechanical properties, it plays an important part in recent years in aerospace,
petroleum and nuclear energy industries. Due to the extreme toughness and work hardening
characteristic of the alloy, the problem of machining Inconel 718 is one of ever-increasing
magnitude. This investigation optimized the machining characteristics of Inconel 718 bars
using tungsten carbide and cermet cutting tools. The approach is based on Taguchi method,
the signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) are employed to study
the performance characteristics in turning operations. The roundness and flank wear of the
ultrasonically and conventionally machined workpieces were measured and compared.
Through this study the optimal cutting parameters for turning operations can be obtained.

Key words: Inconel 718; Ultrasonic; Taguchi method; Flank wear; Roundness

1. Introduction rapidly during machining. Moveover, these

alloys also have a tendency to weld with the
Nickel superalloys are used widely in
tool material at the high temperature
the hottest components and in those
generated during machining. The tendency
subjected to the greatest tensions, they are
to form a built-up-edge (BUE) during
used as well in escape valves, furnace
machining and the presence of hard abrasive
equipment, petroleum and nuclear energy
carbides in their microstructure also deters
industries. The high temperatures that are
machinability [2]. Due to precipitate
generated in the cutting area when the
hardening of γ " secondary phase (Ni3Nb)
machining of nickel-based alloys takes place
together with work-hardening during
are due to the low thermal conductivity and
machining makes the cutting condition even
the minimum thickness of the chip that is
worse. All these difficulties lead to serious
produced during this machining process [1].
tool wear and less material removal rate [3].
The nickel-based alloys have some
characteristics that are responsible for its A study on the performance of
poor machinability, they have an austenitic machinability of Inconel 718 showed that
matrix, and like stainless steels, work harden the tool life of the silicon nitride based
龍華科技大學學報第二十一期,2006.09

material was mainly dependent on flank 2. Experimental design

wear, whereas for the silicon carbide
The difficulty or ease of machining a
whisker-reinforced alumina, the tool life
material is called machinability. According
criterion was depth of cut notch wear [4].
to AISI specifications, the machinability
Two types of coated cemented cardide
rating for free machining steel B1112 is
inserts were used, various combinations of
100% and the machinability rating for
side cutting edge angles (SCEAs), cutting
nickel-based alloy 6~15%, and reflects the
speeds and feedrates were tested at a
difficulty of free machining steel.
constant depth of cut. Cutting results
Machinability ratings for various metals are
indicate the SCEA, together with cutting
shown in Table 1. Tests have been made in
speed and federate, do play a significant role
several laboratories to determine the
in determining the tool life of an inset when
practicability of artificially heating the
machining Inconel 718 [5].
surface of the workpiece just before a cut is
Ultrasonic vibrations have been taken. While the method does not appear to
extensively adopted in manufacturing be of general interest, it may prove to be of
processes. Weber [6] et al. used particular value in the machining of high
high-frequency vibrations (20KHz) in radial temperature alloys where strain hardening is
directions to cut steel materials and found serious [9]. This study gas torch has been
that this approach could increase tool life. employed to heating the workpiece, one
Moreover, Wang and Zhao [7] applied object is to supply enough heat to the
high-frequency vibrations (16KHz) to surface to raise the temperature of a layer
improve surface roughness, reduce micro about equal to the depth of cut to the desired
cracks on the workpiece surface and value.
increase cutting stability. Additionally, C.S.
For cutting speed the amount of nickel
Liu [8] and others proposed using
in a nickel-based high-temperature alloy is
ultrasonic-aided vibrations to cut SiCp/Al
very important. An alloy with a nickel
thin-wall parts for precision processing.
content of about 60 %, and a recommended
Compared with conventional cutting, this
carbide tool speed of 13 m/min were
method is lower in cutting force and does
adopted. This cutting speed would be
not produce BUE.
increased to 20 m/min when machining
This paper discusses the machinability
alloys containing about 50 % Ni, and to 26
of Inconel 718 (ψ70 × 450 mm) by applying
m/min when machining alloys containing 45
a conventional lathe, subjected to various
% Ni [9]. To increase efficiency when
machining parameters including cutting
machining nickel-bases Inconel 718 alloys,
tools for different materials, depth of cut,
this study employed high cutting speed with
cutting speed, feed rate, working
cutting tools for different materials, and
temperature and ultrasonic power. Flank
combined hot machining with
wear of the inserts and workpiece roundness
ultrasonic-aided cutting, to analyze
have been considered.
machining behavior. Based on probes into
 Application of Taguchi method in the optimization of cutting parameters for turning operations

the relevant literature [4,5] and practical best” (NB), and “higher is better” (HB). The
cutting tests, this study selected three cutting S/N ratios were calculated using the
tools, TN35, CT3000 and NX2525, as listed following equations [12]:
in Table 2. This study takes tangent direction S
η = 10 log( ratio) (1)
as the direction of ultrasonic vibration aided N
cutting. S 1
HB: ratio) = 2
(
The Taguchi method is a powerful tool N σ
for designing high quality systems. To 1 1 1 1
σ 2 = ( 2 + 2 + ..... + 2 ) (2)
increase the experimental efficiency, the n y1 y2 yn
L18 mixed orthogonal table in the Taguchi S 1
LB: ( ratio) = 2
quality design [10] is used to determine the N σ
significant machining factors. In the 1
σ 2 = ( y1 2 + y 2 2 + .... + y n 2 )
(3)
experiments, we select six influential n
machining parameters, such as cutting tools Where η denotes the observed value, i.e.,
of different materials, depth of cut, cutting the calculated value of the S/N ratio (unit:
speed, feed rate, working temperature and dB), y n represents the observed value and
ultrasonic power, each of which has three n is the repeated number.
different levels (high, medium and low Table 4(a) lists the experimental results
levels), as shown in Table 3. The machining for roundness and the corresponding
characteristics studied include roundness of signal-noise ratios (S/N) using Eqs.(1) and
the workpiece, and flank wear of the tools. (3). The mean S/N ratio for each level of the
By adjusting experimental combinations and cutting parameters is summarized and called
analyzing experimental results, this work the S/N response table for roundness, the
leads to the optimum cutting parameters. L18 experiments is also calculated and
illustrated in Table 4(b). Fig. 1 shows the
3. Results and analysis of the S/N response graph for roundness, and
experimental indicates that roundness without influence
3.1 Analysis of the S/N ratio from cutting tools, and a smaller feed rate
Classical experimental design methods can obtain better roundness.
are too complex and not easy to use. To To examining the influence of
solve this problem, the Taguchi method uses ultrasonic-aided cutting on roundness, two
a special design of orthogonal arrays to level conjunctions of No.17 and No.18,
study the entire parameter space with a listed in Table 4(a), were used for
small number of experiments [11]. The experiment, and represent the maximum and
Taguchi method employs a generic minimum roundness combinations,
signal-to-noise (S/N) ratio to quantify the respectively, among 18 experimental
present variation. Depending on the combinations. In Table 4(c), the
particular type of characteristics involved, experimental conditions of No.17 and No.18,
different S/N ratios may be applicable, No.17-1 and No.18-1 are cutting with and
including “lower is better” (LB), “nominal is without ultrasonic aid, which obtained
龍華科技大學學報第二十一期,2006.09
average roundness values of 10.03μm and
1.97 μ m, 12.2 μ m and 3.63 μ m,
respectively. The results obtained show that
the application of ultrasonic vibration can
improve the roundness quality considerably.
Improvements of up to 17.78- 45.73% have
been achieved.
This work used an optical microscope
and the Optimas software to inspect the
flank wear. Table 5(a) lists the experimental
results for flank wear and S/N ratios, while
Table 5(b) and Fig. 2 show the S/N response
table and S/N response graph for flank wear.
Fig. 2 indicated that using a cermet cutting
tool NX2525 produces smaller flank wear,
and that the flank wear decreases with
decreasing cut depth.
Generally, most materials soften with
heating to high temperature. However, at an
appropriate temperature, Inconel 718
precipitates the hard second phase ofγ〃
(Ni3Nb), increasing the difficulty of cutting.
Observing the working temperatures level in
Figs. 2 reveals that when a workpiece is
heated for high-temperature (190℃) cutting,
the flank wear increases with temperature.
To inspect the effect of ultrasonic-aided
cutting on flank wear, this investigation
chooses two combinations of No.3 and
No.17 in Table 5(a) for an experiment,
where these two combinations represent the
maximum and minimum flank wear
combinations, respectively, from among 18
combinations examined in the experiment.
In Table 5(c), the experimental conditions of
No.3 and No.17, No.3-1 and No.17-1 are
cutting with and without ultrasonic aid, and
the flank wear measurements are 28.15mm2
and 1.51mm2, 38.31mm2 and 2.81mm2,
respectively. The results obtained show that
the application of ultrasonic vibration can
improve the flank wear quality considerably.
Improvements of up to 26.52- 46.26 % have
been achieved.
Figs. 3(a) and (c) show ultrasonically
aided cutting, which could obtain a low
flank wear of the cutter. Moreover, the BUE
occurs at TN35 tungsten carbide, as shown
in Figs. 3(a) and (b), and is not found at
NX2525 cermet, as illustrated in Figs. 3(c),
(d) and the cutting tool of the NX2525
cermet can obtain a low flank wear (Fig. 2).
3.2 Analysis of variance (ANOVA)
The purpose of the ANOVA is to
investigate the design parameters that
significantly affect the quality characteristic.
The total sum of square SST from the S/N
ratio η can be calculated as [13] :
n
SST = ∑ (η
i =1
i −ηm )2 (4)
Where n is the number of experiments in the
orthogonal array and η i is the mean S/N
ratio for the i th experiment. The sum of
squares from the tested parameter SSP can be
calculated as :
( Sη j ) 2
2
t
1⎡ n ⎤
SSP = ∑
j =1 t
− ⎢∑η i ⎥
n ⎣ i =1 ⎦
(5)
Where p represents one of the tested
parameters, j the level number of this
parameter p, t the repetition of of each level
of the parameter p, Sη j the sum of the S/N
ratio involving this parameter p and level j.
The sum of squares from error
parameters, SSe is
SSe =SST – SSA – SSB – SSC (6)
The total degrees of freedom is DT = m-1,
where the degrees of freedom of the tested
parameter DP = t-1. The variance of the
 Application of Taguchi method in the optimization of cutting parameters for turning operations

parameter tested is VP=SSP/DP. Then, the
F-value for each design parameter is simply
the ratio of the mean-of-squares deviations
to the mean of the squared error (FP=VP/Ve).
* characteristic. The measuring data and the
The corrected sum of squares S P
calculated as:
* in the L18 factors combinations of the two
S P = SSP – DPVe (7)
The percentage contribution ρ can be
calculated as :
* of confirmation experiments are –4.59
S
ρP = P (8)
SS T
Table 6 shows the results of ANOVA
for the roundness and the flank wear. It is
found that depth of cut is the most
significant cutting parameters affecting the
roundness. The change of the cutting speed
and cutting tools are the insignificant effect
on roundness of the machined workpiece.
The results of ANOVA for flank wear (Table
6). The contribution order of the cutting
parameters for flank wear is cutting tools for
different materials, then working
temperature, then ultrasonic power and then
depth of cut.
3.3 Confirmation experiments
Once the optimal level of the design
parameters has been selected, the final step
is to predict and verify the improvement of
the quality characteristic using the optimal
level of the design parameters. The
estimated S/N ratio Ypredicted using the
optimal level of the design parameters can
be calculated as [14] :
k
Ypredicted = Ym + ∑ (Yi − Ym ) (9)
i =1
where Ym is the total mean S/N ratio, Yi
is the mean S/N ratio at the optimal level,
and k is the number of the main design
parameters that affect the quality
can be
actual S/N ratio of confirmation experiments
are listed in Table 7. The largest S/N ratios
types of machining characteristics
were –5.92 (Table 4(a)) and –3.61 (Table
5(a)), respectively. However, the S/N ratios
and –2.10, and both are larger than the
above two. In addition, the S/N prediction,
-5.04 and –1.70, are very close to the actual
value. This finding indicated that the
experiments in this study possess excellent
repetitiveness and great potential for future
references.
4. Conclusion
This paper has discussed an application
of the Taguchi method for optimizing the
cutting parameters in turning Inconel 718
operations. This study discusses six
machining parameters, including cutting
tools for different materials, depth of cut,
cutting speed, feed rate, working
temperature and ultrasonic power. The
machining characteristics studied include
roundness and flank wear. The conclusions
of this study may be summarized as
follows :
1. Formation of built-up-edge (BUE) when
using a NX2525 cermet cutter is far less
than a TN35 tungsten carbide cutter, and
the measured flank wear is lower than
for a TN35 tungsten carbide cutter.
2. When the workpiece underwent high
龍華科技大學學報第二十一期,2006.09
temperature cutting (190℃), owing to the
hard secondary phase of γ ′′ (Ni3Nb)
precipitating, cutting becomes
increasingly difficult, and thus the flank
wear is higher than at room temperature.
3. The percentage contributions of the depth
of cut, ultrasonic power and feed rate for
roundness are 32.96, 12.6, and 12.18,
respectively.
4. The percentage contributions of the
cutting tools, working temperature and
ultrasonic power for flank wear are 31.29,
16.8, and 11.44, respectively.
5. Cutting with ultrasonic aid improved the
roundness by 17.78 % to 45.73 %, as well
as improving flank wear by 26.52 % to
46.26 7%. As a result, ultrasonic aid
cutting can enhance the cutting quality of
Inconel 718.
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 Application of Taguchi method in the optimization of cutting parameters for turning operations

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Table 1. Machinability rates for metals (AISI Specification)

Workpiece Machinablility Workpiece Machinablility
material rate ( %) material rate ( %)

Free machining steel

100 Stainless steel 40～65
(B1112)

Nickel-based alloy 6～15 Titanium 20～30

Cast-iron 50 High-speed steel 30

Pure iron 50 Carbon steel 60～85

Table 2. Cutting tools

Tpye Material Compared with
ISO

TN35 Carbide P20－P40

Coating
Al2O3
CT3000 Cermet P10－P15
M10－M15
K10－K15
NX2525 Cermet P10－P20
K10－K20

Table 3. Setting of factors and levels in experiment

Machining factor Level 1 Level 2 Level 3

S b l
T Cutter TN35 CT3000 NX2525
D Depth of cut 0.1mm 0.2mm 0.3mm
S Cutting speed 22m/min 43m/min 73m/min

F Feed rate 0.054mm/rev 0.103mm/rev 0.147mm/rev

Temp. Working temp. 25℃ 105℃ 190℃

P Ultrasonic power 140 Watt 160 Watt 180 Watt
龍華科技大學學報第二十一期,2006.09

Table 4(a). Experimental results for roundness and S/N ratio

Experiment Control Factors Roundness (μm) S/N
No. (dB)
T D S F Temp. P Rd1 Rd2 Rd3

1 1 1 1 1 1 1 3.60 2.80 2.20 -9.32

2 1 2 2 2 2 2 8.10 9.50 10.10 -19.34
3 1 3 3 3 3 3 3.80 4.10 4.00 -11.97
4 2 1 1 2 2 3 4.20 3.80 4.50 -12.42
5 2 2 2 3 3 1 2.40 5.60 3.90 -12.42
6 2 3 3 1 1 2 4.30 3.20 2.40 -10.61
7 3 1 2 1 3 2 2.70 2.00 2.30 -7.42
8 3 2 3 2 1 3 5.20 5.80 3.20 -13.74
9 3 3 1 3 2 1 5.10 3.10 2.80 -11.61
10 1 1 3 3 2 2 3.80 3.50 4.20 -11.70
11 1 2 1 1 3 3 2.90 2.70 2.80 -8.95
12 1 3 2 2 1 1 4.80 2.50 2.70 -10.86
13 2 1 2 3 1 3 3.00 3.20 2.40 -9.21
14 2 2 3 1 2 1 5.60 3.90 6.00 -14.40
15 2 3 1 2 3 2 1.50 4.00 3.20 -9.78
16 3 1 3 2 3 1 4.70 3.40 4.00 -12.19
17 3 2 1 3 1 2 11.80 10.20 8.10 -20.13
18 3 3 2 1 2 3 2.00 2.20 1.70 -5.92

Table 4(b). S/N response table for roundness

Factors
Level T D S F Temp. P

1 -12.02 -10.38 -12.03 -9.44 -12.31 -11.80

2 -11.47 -14.83 -10.86 -13.05 -12.56 -13.16
3 -11.83 -10.12 -12.43 -12.84 -10.45 -10.37
Level effect 0.55 4.70 1.57 3.62 2.11 2.79
 Application of Taguchi method in the optimization of cutting parameters for turning operations

Table 4(c). An analysis of roundness with and without ultrasonic aid cutting
Experiment Factors Roundness (μm) Mean Improve
value ment.
No. ( μ m) rate
T D S F Temp P Rd1 Rd2 Rd3
(%)
17 3 2 1 3 1 2 11.80 10.20 8.10 10.03 17.78
17-1 3 2 1 3 1 13.10 11.60 11.90 12.20
18 3 3 2 1 2 3 2.00 2.20 1.70 1.97 45.73
18-1 3 3 2 1 2 5.40 1.70 3.80 3.63

Table 5(a). Experimental results for flank wear and S/N ratio
Experiment Factors Flank wear (mm2) S/N
No. T D S F Temp. P A1 A2 A3 (dB)

1 1 1 1 1 1 1 1.61 2.12 4.20 -9.16

2 1 2 2 2 2 2 9.77 8.64 7.64 -18.82
3 1 3 3 3 3 3 45.26 15.33 23.85 -29.78
4 2 1 1 2 2 3 2.03 2.55 3.51 -8.84
5 2 2 2 3 3 1 3.33 5.36 5.44 -13.64
6 2 3 3 1 1 2 4.04 3.33 4.42 -11.94
7 3 1 2 1 3 2 3.07 3.52 3.33 -10.40
8 3 2 3 2 1 3 2.25 1.02 2.10 -5.45
9 3 3 1 3 2 1 1.77 2.04 3.71 -8.46
10 1 1 3 3 2 2 6.63 4.25 3.12 -13.79
11 1 2 1 1 3 3 18.66 15.47 17.23 -24.70
12 1 3 2 2 1 1 14.20 5.62 7.66 -19.88
13 2 1 2 3 1 3 1.05 3.12 3.98 -9.49
14 2 2 3 1 2 1 2.25 1.63 4.41 -9.57
15 2 3 1 2 3 2 6.26 3.06 4.45 -13.58
16 3 1 3 2 3 1 4.20 2.51 3.43 -10.76
17 3 2 1 3 1 2 1.42 1.36 1.74 -3.61
18 3 3 2 1 2 3 4.99 4.92 3.56 -13.14
 龍華科技大學學報第二十一期,2006.09

Table 5(b). S/N response table for flank wear

Level Control factors

T D S F Temp. P

1 -19.35 -10.41 -11.39 -13.15 -9.92 -11.91

2 -11.18 -12.63 -14.23 -12.89 -12.10 -12.02
3 -8.64 -16.13 -13.55 -13.13 -17.14 -15.23
Level effect 10.72 5.73 2.84 0.27 7.22 3.32

Table 5(c). An analysis of flank wear with and without ultrasonic aid cutting
Experiment Factors Flank wear (mm2) Mean Improvement
value rate (%)
No. T D S F Temp P R1 R2 R3 (mm 2
)

3 1 3 3 3 3 3 45.26 15.33 23.85 28.15 26.52

3-1 1 3 3 3 3 23.91 60.59 30.43 38.31
17 3 2 1 3 1 2 1.42 1.36 1.74 1.51 46.26
17-1 3 2 1 3 1 2.71 2.27 3.45 2.81

Table 6 Results of the ANOVA for the roundness and the flank wear
Factor Roundness Factor Flank wear
SS DOF Var F ratio σ(%) SS DOF Var F ratio σ(%)
T 5.56 2 2.78 1.31 2.06 T 879.62 2 439.81 23.97 31.29
D 88.98 2 44.49 20.90 32.96 D 279.18 2 139.59 7.61 9.93
S 1.87 2 0.93 0.44 0.7 S 54.02 2 27.01 1.47 1.92
F 32.89 2 16.45 7.73 12.18 F 51.72 2 25.86 1.41 1.84
Temp. 19.37 2 9.69 4.65 7.17 Temp. 472.29 2 236.14 12.87 16.8
P 34.05 2 17.03 8.00 12.6 P 321.67 2 160.83 8.77 11.44
Error 87.26 41 2.13 32.32 Error 752.24 41 18.35 26.76
Total 269.98 53 100 Total 2810.75 53 100
Note 1: T= Cutter; D= Depth of cut; S= Cutting speed; F= Feed rate; Temp. =Working
temperature; P= Ultrasonic power; σ= Contribution
Note 2: The F ratios according to the F distribution table for roundness is
F(0.05, 2, 41)=3.2
The F ratios according to the F distribution table for flank wear is
F(0.01, 2, 41)=5.2
 Application of Taguchi method in the optimization of cutting parameters for turning operations

Table 7 Results of the confirmation experiment for the surface roughness and
the cutting force
Control factors S/N (dB) Confirmation experiments
prediction
T D S F Temp. P Measuring Mean S/N
data value (dB)
Roundness CT3000 0.3 43 0.054 190℃ 180
mm m/min mm/rev Watt -5.04 1.75 1.90 1.40 1.68 -4.59
flank wear NX2525 0.1 22 0.103 25℃ 140
mm m/min mm/rev Watt -1.70 1.24 1.08 1.47 1.26 -2.10

-6

-8
S/N ratio of roundness (db)

-10

-12

-14

-16

-18

Cutter Depth Speed Feed Temp. Power

„TN35 „0.1mm „22m/min „0.054mm/tooth „25℃ „140 Watt

zCT3000 z0.2mm z43m/min z0.103mm/tooth z105℃ z160 Watt

▲NX2525 ▲0.3mm ▲73m/min ▲0.147mm/tooth ▲190℃ ▲180 Watt

Figure 1. S/N graph for roundness

龍華科技大學學報第二十一期,2006.09

-7

-9
S/N ratio of flank wear (db)

-11

-13

-15

-17

-19

-21

Cutter Depth Speed Feed Temp. Power

„TN35 „0.1mm „22m/min „0.054mm/tooth „25℃ „140 Watt

zCT3000 z0.2mm z43m/min z0.103mm/tooth z105℃ z160 Watt

▲NX2525 ▲0.3mm ▲73m/min ▲0.147mm/tooth ▲190℃ ▲180 Watt

Figure 2. S/N graph for flank wear

 Application of Taguchi method in the optimization of cutting parameters for turning operations

Flank wear BUE Flank wear BUE

100μm
100μm

(a). Cutting with ultrasonic aid (b). Cutting without ultrasonic aid
Cutting tool: TN35, Depth of cut: Cutting tool:TN35, Depth of cut:
0.3mm 0.3mm
Cutting speed: 73m/min, Feed: Cuttingspeed:73m/min,Feed:
0.147mm/rev. 0.147mm/rev.
Working temp.: 190℃ Working temp.: 190℃
Ultra. Power: 180 Watt, Frequency: Ultra. Power: 0, Frequency: 0
20KHz Flank wear area: 23.91mm2
Flank wear area: 15.33mm2
Flank wear zone No BUE
Flank wear zone No BUE

100μm
100μm

(c). Cutting with ultrasonic aid (d). Cutting without ultrasonic aid
Cutting tool: NX2525, Depth of cut: Cutting tool：NX2525，Depth of cut:
0.2mm 0.2mm
Cutting speed: 22m/min, Feed: Cutting speed: 22m/min, Feed:
0.147mm/rev. 0.147mm/rev.
Working temp.: 25℃ Working temp.: 25℃
Ultra. Power: 160 Watt, Frequency: Ultra. Power: 0, Frequency: 0
20KHz
Flank wear area: 3.45 mm2
2
Flank wear area: 1.36 mm

Figure 3. Comparisons of flank wear with and without ultrasonic aid cutting
龍華科技大學學報第二十一期,2006.09

應用田口實驗法尋求最佳車削參數之研究

鄒貴鉅 1* 陳釘煙 2 許春耀 1

1 2
龍華科技大學 機械系 華夏技術學院 機械系

摘要
Inconel 718 為析出硬化型鎳基高溫超合金(Ni-Base Superalloy)，在-250～700
℃之超低溫及中高溫環境具有優良的機械性質，近年來廣泛應用在航太零組件、石化及
核能反應器等工業上。Inconel 718 合金具有沃斯田鐵型的基地，其中鈮(Nb)之含量又
較其他耐熱超合金高，在切削壓力及熱量輸入時容易析出γ〞(Ni3Nb)之堅硬二次相，造
成切削時嚴重之加工硬化進而導致刀具磨耗，母材優異的機械性質，使得金屬移除率較
低，從鎳基超合金發展以來，其加工效率一直是專家學者研究的重點。本研究的目的為
應用田口實驗計畫法，以碳化鎢及瓷金為刀具，配合超音波輔助振動及工件加熱進行高
溫切削，尋求 Inconel 718 的最佳切削參數。文中比較使用及不使用超音波輔助振動，
對工件真圓度及刀腹磨耗的改善程度。經由本研究結果獲得最佳車削 Inconel 718 的參
數組合。

關鍵字: 鎳基高溫超合金、超音波振動、田口實驗法、刀腹磨耗、真圓度