Effect of ultrasonic-assisted turning on geometrical tolerances in Al 2024-T6

Abstract

ABSTRACT In this research, the effect of ultrasonic vibrations in the turning process on geometric tolerances has been investigated. This has always been one of the most important challenges in the production of high-quality and precision parts. One of the important applications of the turning process is making parts with high dimensional accuracy. In this study, by applying ultrasonic vibrations to different machining parameters, we investigated the surface quality, runout, total runout, and straightness tolerance of a 2024-T6 aluminum workpiece. In the second stage, the effect of the presence of ultrasonic vibrations was investigated. The full factorial experiment design method was used, and 18 experiments were performed with this method. After that, the results were analyzed, and they are as follows. Compared to other machining parameters, the cutting speed has the highest effect on the runout, total runout, straightness tolerance, and surface roughness. Ultrasonic vibrations reduce all four output parameters of runout, total runout, straightness tolerance, and surface roughness. In particular, the surface roughness in ultrasonic turning decreased compared to conventional turning. Also, the formation of chips was investigated. This technique is suitable in manufacturing industries that require high dimensional accuracy.