Research on optimization of cutting force in AISI D2 hardened steel ultrasonic vibration-assisted turning

Abstract

This study utilized the self-developed ultrasonic vibration-assisted turning system to conduct turning experiments on AISI D2 hardened steel. The investigation is carried out by the Robust Design method via controlling different ultrasonic vibration-assisted turning factors and levels, including feed rate, spindle speed, depth of cut, and the magnitude of amplitude of the ultrasonic vibration tool tip. This study is carried out with optimal cutting force by the Robust Design goals. The optimal combination is A1 (0.5 mm depth of cut) B1 (0.08 mm/rev feed rate) C3 (20 μm amplitude) D2 (885 rpm spindle speed). The cutting force is 119.85 N which hugely decreased 28.6% by comparing with the lowest group. Through analysis of variance, the depth of cut and feed rate play a dominant role in cutting force. These two factors are used for obtaining the difference of cutting force and tool wear by comparing the two factors at different levels. The experimental results show that the optimal depth of cut and feed rate can be reduced by 15.8% and 28.4% in cutting force, and 72% and 81% in tool wear compared with other levels. When turning AISI D2 hardened steel, ultrasonic vibration-assisted turning systems can greatly improve the turning efficiency.