Abstract
Conventional Turning (CT) is being used traditionally for machining various materials, but CT lacks productivity, as it results in rapid tool wear and poor surface finish. To overcome these problems, recently, Ultrasonic Assisted Turning (UAT) process has emerged as a potential solution. Recent studies done on the UAT process have shown noticeable enhancement in tool life, chip morphology, and surface finish. These outcomes have attracted the research community towards further development of the UAT process. This study presents a comparison between the UAT and the CT processes for the turning of the AISI 420 stainless steel. In this context, the full factorial methodology is used for designing the experiment. Factors chosen for the experiment are feed and spindle rotation speed having three levels of each. The three responses selected for this study are namely surface roughness parameters (Ra, Rz and, Rt), power consumption, and chip morphology. An approximated reduction of 43% in the surface roughness value Ra and a marginal reduction of 3.13% in power consumption is observed for the UAT process. Discontinuous and segmented chip formation is observed for the UAT process, while the continuous chip is observed for the CT process.
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