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In this article, surface roughness, cutting forces and material removal rates of different materials are investigated in different cutting conditions in turning operations. First, vibration characteristics (natural and chatter frequency, stiffness coefficient and damping ratio) are determined by modal analysis and different cutting tests. Surface roughness, material removal rate and cutting forces were measured during experiments. By using these experiments, five different hybrid multi-criteria decision making models are proposed. Cutting parameters are optimized by maximizing material removal rate and minimizing surface roughness and cutting force.

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Aviation alloys exhibit superior properties such as high-strength-to-weight ratio and corrosion resistance but these alloys possess poor machinability. To overcome this disadvantage, new machining methods (Ultrasonic assisted machining, hot machining, etc.) are developed. Hot ultrasonic assisted turning (HUAT) is a new hybrid machining method which changes the cutting system between tool and workpiece, therefore, reduced cutting forces and better surface finish for workpiece are obtained. In this study, 2D finite element (FE) analysis is carried out to investigate the effects of these machining methods on titanium and Hastelloy-X alloys in terms of cutting forces, cutting tool temperatures and effective stresses. DEFORM-2D software is used during analyses. In addition, an experimental study is conducted to verify numerical results. During verification, cutting tool temperature is taken into consideration. It is confirmed that HUAT technique reduces cutting forces and effective stress significantly but cutting temperature increases compared to conventional and ultrasonic assisted turning. Keywords Finite element modeling Á Hot ultrasonic assisted machining Á Titanium alloys Á Ultrasonic assisted machining Á Hot machining Á Hastelloy-X