Process parameters influence on cutting force and surface roughness during hybrid laser- and ultrasonic elliptical vibration-assisted machining

Abstract

Ultrasonic elliptical vibration-assisted machining (UEAM) and laser-assisted machining (LAM) are considered as hybrid machining processes, in which 2D ultrasonic vibrations and heat are used to improve metal cutting process; in the present study, a series of experimental tests with the aim of measuring cutting forces and workpiece surface roughness in hybrid laser- and ultrasonic elliptical vibration-assisted machining (HL-UEAM) are conducted to evaluate the effect of process parameters including un-deformed chip temperature, vibration amplitude, work velocity and feed. A statistical analysis has been performed on the data obtained from the experiments, and the main effect of parameters as well as their interaction effects on process outputs is analyzed. The results revealed the reductions of 43, 54 and 75% in the main component of cutting force can be achieved in LAM, UEAM and HL-UEAM compared to conventional turning (CT), respectively. Therefore, from the force reduction perspective, simultaneous application of laser and ultrasonic elliptical vibrations would be more effective than their separate usage. The results of surface roughness measurement declared the approximately 20% increase in surface roughness by UEAM compared to CT. However, HL-UEAM surface roughness measurement shows approximately 35% enhancement compared to CT.