Surface Topography in Cutting-Speed-Direction Ultrasonic-Assisted Turning.

Area of Science:

• Manufacturing Engineering
• Materials Science
• Mechanical Engineering

Background:

• Ultrasonic vibration in turning reduces cutting forces, tool wear, and improves surface finish.
• Achieving intermittent cutting requires specific conditions below critical speeds related to vibration parameters.

Purpose of the Study:

• To develop a theoretical model for surface formation in cutting-speed-direction ultrasonic-assisted turning (CUAT).
• To experimentally validate the model for both continuous and intermittent machining regimes across different materials.
• To evaluate the impact of CUAT on surface roughness compared to conventional turning (CT).

Main Methods:

• Development of a theoretical model for surface topography in CUAT.
• Experimental validation using C45 carbon steel and 201 stainless steel.
• Surface roughness analysis using digital microscopy and Ra measurements.

Main Results:

• The theoretical model accurately predicted 3D topography for both materials.
• CUAT significantly reduced surface roughness (Ra) by up to 80% for C45 steel compared to CT.
• CUAT showed minimal roughness improvement for 201 stainless steel, with only slight fluctuations.

Conclusions:

• The developed theoretical model is applicable to predicting surface formation in CUAT across different materials.
• CUAT offers substantial surface roughness improvements for certain materials like C45 steel.
• Material properties influence the effectiveness of CUAT in reducing surface roughness.