Inconel 718 has excellent thermal and chemical properties and is widely used in the manufacture of aerospace parts; however, there are some problems in the machining of Inconel 718, such as a large milling force, serious tool wear, and poor surface quality. In this research, a type of longitudinal–torsional ultrasonic milling (LTUM) tool is designed based on theoretical computations and FEM simulation analysis. To verify the design rationality of the developed LTUM tool, milling experiments are performed. It is verified that the LTUM tool can realize an elliptical vibration path at the tool tip. The resonance frequency of the tool is 21.32 kHz, the longitudinal amplitude is 6.8 µm, and the torsional amplitude is 1.4 µm. In the milling of Inconel 718, the experimental data of LTUM are compared with those of conventional milling (CM). The comparative experiments show that the LTUM tool can effectively lessen the milling force and tool wear in the milling of Inconel 718, improve the surface quality, inhibit the generation of burrs, and improve the chip breaking ability. The application potential of the LTUM tool in high-performance milling of Inconel 718 parts is proven.

Accurate online acquisition of tool wear degradation indicators is an important prerequisite for tool wear monitoring and tool remaining life prediction. The tool degradation process is usually accompanied by the flank face of cutting tool wear and blade breakage, however, the existing degradation indicators only consider the flank face wear value, but not the tool breakage value, resulting in the lack of accuracy of degradation indicators. To this end, an online identification method of tool degradation indicators based on the fusion of image sensors and laser displacement sensors is proposed, which adopts the VGG16-UNet network to identify the wear value in the image and obtains the tool breakage value based on the time series data of the laser displacement sensor. Finally, the tool wear and breakage degradation label containing wear and breakage values is established. Compared to manual measurements, the absolute average error is within 15 µms for cutter face damage values and within 3 µms for cutter face wear values.

As a veneering porcelain coating of dental prosthesis, two-body and three-body wear behavior of dental glass-ceramic with the main crystalline phase of fluorapatite has not been comprehensively studied. In this work, a self-made fluorapatite glass-ceramic was synthesized and the mechanical and tribological performances of the glass-ceramic were tested, comparing with a commercial feldspathic glass-ceramic. The friction and wear experiments were performed between disk-shaped glass-ceramics and natural teeth in two-body (dry, water, saliva) and three-body (slurry) modes, respectively. Results showed that good mechanical properties of fluorapatite glass-ceramic can be achieved by the sintering process. In both two-body and three-body modes, the fluorapatite glass-ceramic had a smaller friction coefficient and wear rate and caused less damage on antagonistic teeth than the feldspathic glass-ceramic. The greater mechanical properties give fluorapatite glass-ceramic a better wear resistance and reduce the adhesive wear.