Performance evaluation of surface-active-medium assisted ultrasonic grinding for Inconel-718

Inconel-718 is widely utilized in the aerospace and defense industries owing to its exceptional strength and thermal resistance. However, these properties make grinding difficult, often leading to rapid tool wear and poor surface quality. This study experimentally evaluates the use of an ecofriendly surface-active medium (SAM) with ultrasonic-assisted surface grinding (USG) as part of an advanced manufacturing process. The goal is to improve machining performance while reducing cutting force and material usage. To evaluate the efficacy of the proposed strategy, the key processing parameters considered are the depth of cut a_p (15–35 μm), spindle speed ω (8000–16000 rpm), ultrasonic amplitude A (2–10 μm), and feed rate f_r (5–25 mm/min). The results indicate that the integration of an SAM with high-frequency vibrations significantly reduces grinding forces (by up to 39.86%), enhances tool life, and improve surface finish by as much as 56.8%. Additionally, the optimal cutting conditions (a_p = 30 μm, A = 10 μm, ω = 16000 rpm, and f_r = 20 mm/min) are found to provide superior cutting performance. The proposed sustainable method demonstrates considerable potential for machining Inconel-718 using better machining processes.