Hybrid turning process by interacting ultrasonic vibration and laser energies

Deswal, Neeraj; Kant, Ravi

doi:10.1080/10426914.2022.2065014

Cited by 11 publications

(8 citation statements)

References 29 publications

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“…The workpiece material became softened due to this reason crack-free chips and higher chip thickness were generated for the UVLAT process. Moreover, the cracks were found to be reduced with an increase in laser power due to the ductile chip formation during the UVLAT process, according to Deswal and Kant [23]. They illustrated that the chip generation phenomenon was improved during the UVLAT process because of the generation of lower machining forces and higher machining temperature in the UVLAT process.…”

Section: Chip Morphologymentioning

confidence: 98%

“…The machining temperature was measured by a FLIR A315 thermal imaging camera and the data was analyzed by FLIR Tools+ software. The emissivity of the aluminium 3003 alloy was considered as 0.06, as per the literature [23]. The chip morphology and surface damage of aluminium 3003 alloy were analyzed by a Jeol JSM-6610LV scanning electron microscope.…”

Section: Machining Performance Evaluationmentioning

confidence: 99%

“…The cutting tool was engaged and disengaged periodically due to the ultrasonic vibration energy, and the workpiece material was thermally softened due to the localized melting by the laser heating, simultaneously during the UVLAT process which led to a higher reduction in machining forces. Deswal and Kant explained that the combined interaction of laser and ultrasonic vibration energies led to a reduction in machining forces because of the cutting tool periodic separation characteristics and thermal softening of workpiece material, simultaneously during the UVLAT process [23]. Apart from that, the reduction in machining forces was more pronounced for higher laser power during the UVLAT process.…”

Section: Machining Forcesmentioning

confidence: 99%

“…Statistical analysis revealed a 75% reduction in machining forces and a 35% reduction in surface roughness for the hybrid machining process than the CT process [22]. Deswal and Kant combined laser and ultrasonic vibration energies in the feed direction, simultaneously in the turning process and found improvement in machining forces, chip morphology, and surface roughness for the hybrid machining process than that of the CT process [23]. Apart from that, the combined laser and ultrasonic and vibration energies have also been employed in the tangential direction and revealed significant improvement in the machining performance for the hybrid machining process compared to the CT process [24].…”

Section: Introductionmentioning

confidence: 99%

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Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

Deswal

Kant

2023

Mater. Res. Express

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The utilization of various energy sources to assist the machining process has become prominent to achieve substantial improvement in machining performance. These energy sources have also resulted in an alternative to cutting fluids which is safer for both the universe and human beings. The combined action of laser and ultrasonic vibration energies during the turning process has shown significant achievement in machining process capabilities. Therefore, an attempt has been made to provide ultrasonic vibration in the radial direction and laser to preheat aluminium 3003 alloy simultaneously during the ultrasonic-vibration-laser assisted turning (UVLAT) process. Machining performance has been analyzed in terms of machining forces, machining temperature, chip morphology, surface damage, and surface roughness. A comparative machining performance analysis has been carried out among the conventional turning (CT), laser assisted turning (LAT), ultrasonic vibration assisted turning (UVAT), and UVLAT processes. The outcomes of the current study indicate significant benefits of the UVLAT process on the machining performance of aluminium 3003 alloy. However, surface damage and surface roughness have been affected negatively during the UVLAT process due to the pin-point hammering and particle adhesion on the workpiece part. Hence, the selection of vibration direction is a critical factor during the vibration machining processes.

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Section: Chip Morphologymentioning

confidence: 98%

Section: Machining Performance Evaluationmentioning

confidence: 99%

Section: Machining Forcesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

Deswal

Kant

2023

Mater. Res. Express

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“…They observed that UAT minimises the power consumption and surface roughness compared to CT under MQL and LCO 2 . Deswal et al 23 found that UVAT produces lower machining forces, surface roughness and tool wear compared to CT in their studies on magnesium AZ31B alloy. Also, the authors observed that UVAT generated higher microhardness compared to CT. Airao et al 24 studied the effect of ultrasonic vibration under vegetable based cutting fluid lubrication during the machining of titanium 64.…”

Section: Introductionmentioning

confidence: 98%

Experimental investigation on the machining performance of AISI D2 tool steel during ultrasonic-assisted turning under dry and MQL conditions

Umasekar

John

2023

Proceedings of the Institution of Mechanical Engineers, Part E:

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Ultrasonic-assisted turning (UAT) is a hybrid machining method that improves difficult-to-cut materials’ machinability and surface integrity. Minimum quantity lubrication (MQL) is a cooling condition employed in metal cutting operations to improve machining performance and environmental sustainability. This article presents the experimental investigations on the effect of machining and vibration parameters and cooling conditions on the surface roughness (Ra), flank wear (Vb), and surface hardness (HV) during UAT of AISI D2 tool steel. Experiments were designed based on L36 orthogonal array. Two levels of spindle speeds, feed rates, depth of cut, and three levels of percentage intensity of ultrasonic power (PIUP) were employed, and two cooling conditions, like dry and MQL. Analysis of variance (ANOVA) was used to find the significant input parameters that affect each response. ANOVA output revealed that feed rate was the most influential factor on Ra, the PUIP is the dominant factor on HV, and spindle speed is the significant factor on Vb. Optimisation is performed to find optimal parameters as per Taguchi multi-response method. The optimal parameters are 450 rpm spindle speed, 0.05 mm/rev feed rate, 0.1 mm depth of cut, 100 PIUP and MQL cooling resulted in minimum surface roughness of 0.439 μm, maximum hardness of 283 HV and minimum flank wear of 168 μm. Flank wear morphology results showed that abrasion and chipping are the tool wear mechanism in dry UAT, whereas minor abrasion alone was found in MQL UAT compared to CT. Chip morphology study showed that UAT produced continuous spiral-type chips under both cooling conditions compared to CT. A novel design approach is implemented to design the UAT tool. Along with the UAT tool, MQL is also given to improve the machinability of D2 tool steel. This UAT tool can machine intricate metals with a critical cutting velocity of less than 75.4 m/min.

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Experimental study of surface integrity in ultrasonic vibration–assisted milling of GH4169 nickel-based superalloy

Sun,

Li,

Zhang

et al. 2023

Int J Adv Manuf Technol

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Hybrid turning process by interacting ultrasonic vibration and laser energies

Cited by 11 publications

References 29 publications

Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

Experimental investigation on the machining performance of AISI D2 tool steel during ultrasonic-assisted turning under dry and MQL conditions

Experimental study of surface integrity in ultrasonic vibration–assisted milling of GH4169 nickel-based superalloy

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