Machining Difficulties Research Articles

Micro-machining of Monel K500 using electrical discharge drilling: insights into hole tapering mechanism and surface morphology

Abstract Monel K500, a corrosion-resistant nickel-copper alloy, presents machining difficulties because of its hardness and toughness. Consequently, the efficacy of non-conventional machining processes on this material demands investigation. Substantial research on micro-feature manufacturing on Monel K500 utilizing the micro-electrical discharge drilling (MEDD) technique remains unreported. This investigation is an attempt to study the micro-machining performance of Monel K500 while fabricating through-micro-holes using MEDD process. The one-factor-at-a-time (OFAT) approach was adopted to arrive at the optimal combination of voltage (V), capacitance (C), tool speed (TS), and pulse duration (PD) for the best output responses. There is a scarcity of extensive investigations on the tapering mechanism in Monel K500 MEDD, such as the one conducted in this study. The value of material removal rate (MRR) at 160 volts was 7.73 × 10−5 g min−1 with 100 pF capacitance, 200 rpm tool speed, and 5 μs pulse duration. At 220 volts, the MRR increased by 50.06% with the same capacitance, tool speed, and pulse length values, reaching 11.60 × 10−5 g min−1. The values of V, C, TS, and PD corresponding to the optimal combination of MRR (35.68 × 10−5 g min−1) and machining time (MT) (16.19 min) were 220 volts, 10000 pF, 400 rpm, and 20 μs respectively. The micrographs of the machined specimens depicted deviation in hole diameter and the presence of tapering in the though-micro-holes. The study revealed that a micro-hole, machined at low discharge energy (DE), has a smoother surface and more uniform size than one machined at higher DE. Monel K500 is extensively utilized in the aerospace, marine, and chemical sectors because to its superior mechanical qualities and corrosion resistance. A standard set of efficient machining conditions can aid in the accurate manufacturing of Monel K500 components with intricate features via the MEDD process.

Electrochemical Properties and Jet Electrochemical Micromilling of (TiB+TiC)/Ti6Al4V Composites in NaCl+NaNO3 Mixed Electrolyte.

Difficult-to-cut titanium matrix composites (TiB+TiC)/Ti6Al4V have extensive application prospects in the fields of biomedical and aerospace metal microcomponents due to their excellent mechanical properties. Jet electrochemical micromilling (JEMM) technology is an ideal method for machining microstructures that leverages the principle of electrochemical anodic dissolution. However, the matrix Ti6Al4V is susceptible to passivation during electrochemical milling, and the inclusion of high-strength TiB whiskers and TiC particles as reinforcing phases further increases the machining difficulty of (TiB+TiC)/Ti6Al4V. In this study, a novel approach using NaCl+NaNO3 mixed electrolyte for the JEMM of (TiB+TiC)/Ti6Al4V was adopted. Electrochemical behaviors were measured in NaCl and NaCl+NaNO3 electrolytes. In the mixed electrolyte, a higher transpassive potential was required to break down the passive film, which led to better corrosion resistance of (TiB+TiC)/Ti6Al4V, and the exposed reinforcing phases on the dissolved surface were significantly reduced. The results of the JEMM machining indicate that, compared to NaCl electrolyte, using mixed electrolyte effectively mitigates stray corrosion at the edges of micro-grooves and markedly improves the uniformity of both groove depth and width dimensions. Additionally, the surface quality was noticeably improved, with a reduction in Ra from 2.84 μm to 1.03 μm and in Rq from 3.41 μm to 1.40 μm.

Investigation on cutting forces in ultrasonic vibration assisted milling of particle-reinforced titanium matrix composites (PTMCs)

Particle-reinforced titanium matrix composites are widely used in aerospace and marine fields because of their excellent performance. However, the difficulty of machining is increased by the existence of highly brittle and hard reinforcing particles dispersed in the matrix. To address the challenges of the difficulty of subsequent processing of particle-reinforced titanium matrix composites, an ultrasonic vibration-assisted process is used for milling. In this paper, an orthogonal cutting simulation model of particle-reinforced titanium matrix composites’ material is established by ABAQUS software, and the constitutive material models of particles and metallic matrix are established respectively. The excellent performance of ultrasonic vibration assisted cutting is dynamically analyzed from the simulation micro angle. Meanwhile, combined with the conventional milling and ultrasonic vibration assisted cutting experiments, the influence of the two processing methods on the cutting performance of grain-reinforced titanium matrix composite material is compared. The results show that, compared with conventional milling, the intermittent cutting mode of ultrasonic vibration-assisted cutting can significantly reduce the cutting force by about 10%; in both cutting modes, with the same cutting conditions, the change in cutting force is positively correlated with the cutting speed, feed per tooth, and cutting width.

Evaluation of the Surface Integrity and Recast Layer in Electrical Discharge Turning of WC-Co Composites.

Tungsten carbide (WC) and its composites are typically associated with high hardness and high wear resistance, posing challenges in conventional machining processes like turning. To address the machining difficulties of WC-Co, electrical discharge turning (EDT) was proposed. The rotational speed in EDT is a key factor influencing the machining results; however, conflicting reports exist about its impact on the EDT process. Therefore, the effect of rotational speed on three different machining regimes, including roughing, semi-finishing, and finishing, was investigated using energy-dispersive X-ray spectroscopy (EDX), SEM, and roughness tests. Additionally, elemental mapping was applied to illustrate the element distribution on the machined surface. The results indicated that increasing the rotational speed led to a 10% to 17% decrease in the recast layer thickness and a 14% to 54% reduction in the surface roughness (Ra).

The ablation behavior and modification mechanism of SiC under different laser energy

The laser modification pretreatment method is an effective way to address the machining difficulties of silicon carbide (SiC), a typical hard-to-machine material. Therefore, the ablation behavior and modification mechanism of SiC under different laser energy were explored in this paper. A new multi-scale model of laser irradiation SiC that couples heat transfer and fluid motion is first established. Then, a series of experiments is carried out to evaluate the model's accuracy, and the interaction between laser and SiC is discussed in detail. The results show that the dominant modification mechanism changes from coulomb explosion to multiphoton absorption, incubation effect, and heat accumulation with the laser energy increase. This leads the surface topography of SiC to transition from nanoparticle formation to disorder to a melting state. In ablative state, micro/nano porous and humps are formed at the edge of ablation groove due to surface tension, generation and rupture of bubbles, respectively. Furthermore, the surface roughness is not proportional to the laser energy due to the plasma shielding effect, and the surface roughness can be reduced by enhancing the flow of the molten material. Amorphous Si–O–C, Si and spherical SiO2 exist in deposition area, leading to SiC elastic modulus decreases from 347 GPa to 103.82 GPa, and the shear strength decreases from 20.9 GPa to 17.25 GPa. The results of this study can provide references for parameters selection and theoretical support for improving the machinability of SiC.

Study of the corrosion resistance of high chromium white cast iron welds in the presence of NaOH (30% w/w)

– In the mining industry, specifically in bauxite processing, adverse working conditions demand high mechanical and chemical resistance. For such conditions, the choice of potentially resistant materials, such as high chromium white cast iron (HCr-CWI), is necessary. However, presently, there is no effective recovery of equipment made with HCr-CWI, primarily due to the machining difficulties encountered during the repair process. An alternative recovery method is being developed by the Laboratory of Metallic Materials Characterization at UFPA – LCAM, using electric arc welding with two filler metals: the ER307L stainless steel wire andsa high Mn value wire. Within this context, this study aims to investigate the corrosion resistance of the welded joint obtained with these two filler metals. The base metal (HCr-CWI) was analysed as a reference, alongside the metals generated by the welded joints, ER307L and high Mn. The samples underwent tests involving optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and electrochemical tests for corrosion potential, polarization, and impedance. It was observed that the samples exhibited a similar matrix-carbide structure but with different organization and volumes. However, the electrochemical behaviour in terms of corrosion potential, polarization, and impedance was similar, with very close resultant values: 50 V; 3.53 μA; 0.18 kOhms, respectively. This was supported by the corrosion rate of 0.4mmpy and explained by calculations of Cr and Ni volume, which showed inverse concentration magnitudes among the samples.

Experimental investigation to assess the surface integrity in WEDM of Al-based hybrid composite material

Aluminum-based hybrid composites are used in various engineering applications due to their unique properties, such as high strength, good wear resistance, excellent corrosion resistance, and low density. Aluminum metal matrix (AMMC) composites reinforced with ceramic particles can be more difficult to machine than traditional aluminum alloys because of their increased hardness and abrasiveness. Wire electric discharge machining is a non-traditional machining process that uses a thin metal wire, typically made of molybdenum, brass or tungsten to cut through a workpiece using electrical discharge sparks. This process is useful for precision machining of complex shapes and profiles in hard or difficult to machine materials. WEDM is a commonly used process for cutting Al-SiC-ZrO2 HAMMCs due to their hardness and difficulty in machining using conventional techniques. The present study examines the relationship between machining parameters like pulse on time (TON), pulse off time (TOFF), peak current (IP) and wire feed (WF) and material removal rate (MRR) and surface roughness ( Ra) for Al-SiC-ZrO2 in WEDM. The Box-Beckham Design was used to plan the experiments, and response surface method was employed to develop the models. The pulse duration, TOFF, IP, and quadratic terms of [Formula: see text] and [Formula: see text] are the most influential factors of the MRR. The TON, IP and interaction term (TON × IP), and [Formula: see text] were the most significant factors for Ra. Multi-response optimization of process parameters was obtained using the desirability function approach. Furthermore, the machined samples were analyzed for surface integrity using SEM techniques. The prediction from this model validated the confirmation results.

Effect of Minimum Quantity of Lubricant on Carbide Tools and Surface Integrity in the Machining of Titanium Aluminides

Titanium aluminides are being explored as potential materials for the aeronautical sector. However, their application is limited by the high costs of processing and their difficulties in machining. This research evaluates the effectiveness of the minimum quantity lubrication technique (MQL) on the turning process of Ti48Al2Cr2Nb aluminide in terms of tool wear, tool life, cutting forces, surface integrity, and temperature. It was found that MQL conditions can improve the process efficiency, reducing the thermally induced wear mechanisms and enlarging the tool life compared to dry machining. Furthermore, it allows the cutting speed to be incremented, leading to lower processing times. However, MQL seems to not be effective in the reduction of the strain-hardening effect near the machined surface and, although the number of microcracks is reduced, defect-free surfaces cannot be obtained. Moreover, similar microstructural alterations as for dry cutting were detected. The best cutting conditions in terms of surface quality were assessed using the central composite face (CCF) design and surface response methodology. Optimization of the surface roughness under industrially viable cutting conditions was achieved with an average surface roughness value, Ra, of 0.29 µm (feed rate of 0.05 mm/rev, a cutting speed of 54.6 m/min and a depth of cut of 0.125 mm).

Application of minimum quantity GnP nanofluid and cryogenic LN2 in the machining of Hastelloy C276

The current study delves into the combined influence of lubrication and cooling on the machinability of a difficult-to-cut superalloy. A comparative study of four lubricating mediums—dry, Minimum Quantity Lubrication (MQL), nanoMQL (NMQL), and Cryo-NMQL—was conducted during the milling of Hastelloy C276. Findings reveal that the Cryo-NMQL medium resulted in a 25.49%, 29.84%, and 42.50% decrease in cutting force, cutting temperature, and surface roughness, respectively, compared to dry cutting. This lubricating medium also decreased tool wear by 44.55%, as confirmed by SEM images showing reduced adhesion and abrasion. Analysis of chip morphology indicated a finer lamella structure with minimal serration under Cryo-NMQL, indicating enhanced efficiency. Furthermore, Cryo-NMQL refined the grain structure, enhancing microhardness for improved superalloy machining. ANOVA analysis identified feed rate and cutting speed as the most impactful parameters affecting the machining responses. Lastly, based on MORSM analysis, optimal machining parameters were determined as a cutting speed of 76.60 m/min, feed rate of 0.12 mm/tooth, radial depth of cut of 6.7 mm, and axial depth of cut of 0.6 mm. Experimental and predicted values closely matched, with a composite desirability score of 0.912, showcasing the efficacy of MORSM in addressing machining difficulties. This holistic investigation underscores Cryo-NMQL as a promising solution for the efficient and effective machining of superalloys.

Forming Technology of a High-Frequency Conical Spiral Antenna

This paper introduces the integrated stereo forming technology of high-frequency conical spiral antenna, focusing on the material selection and processing of the supporting substrate, the surface metallization technology of the substrate, the establishment of spiral CNC machining models, and the control of CNC machining difficulties. The technology has been successfully applied in engineering, ensuring the continuity and consistency of three-dimensional microstrip in space. It also resolves the offset address problems of docking ends and ports asymmetry caused by microstrip splicing technology. The advantages of this technology include high processing accuracy, good consistency, high stability, and short processing cycle. The high-frequency conical spiral antenna produced has been verified by antenna testing, adaptability tests of mechanical environment and temperature environment, and its performance is stable, which can meet the requirement of the design and application. It has been successfully applied to electronic countermeasures equipment. The test results indicate that the high-frequency conical spiral antenna has good electrical performance and consistency. So the integrated stereo forming technology for high-frequency conical spiral antenna is feasible and reliable. This provides a useful reference for the research on the similar products processability.

An SIW Quasi-Pyramid Horn Antenna Based on Patch Coupling Feed for Automotive Radar Sensors

An SIW quasi-pyramidal horn antenna based on patch coupling feed with reduced machining difficulty and facilitated integration with the radar chip is proposed in this paper. Compared with the metal pyramid horn antenna, the Rogers 5880 dielectric substrate based on the SIW structure is used to form the horn structure and waveguide structure, which effectively reduces the difficulty of machining the antenna. The patch coupling feed structure provides a solution for integrating the SIW quasi-pyramid horn antenna with the radar chip. The proposed SIW quasi-pyramid horn antenna element achieves approximately 9 dBi realized gain, about 95% radiation efficiency and 8.2 GHz bandwidth (74.1–82.3 GHz). A four-port inverting power divider was designed to verify the feasibility of forming an array with antenna elements. The designed antenna array achieves approximately 14.5 dBi realized gain, about 80% radiation efficiency and 7.2 GHz bandwidth (74.3–81.5 GHz). Simulation and measurement results maintain good agreement for the antenna array. To further assess the impact of errors on the performance of the proposed antenna array, we have implemented a corresponding error analysis. The proposed antenna element and antenna array show promising potential for application in automotive radar systems.

Electrode-assisted hydrodynamic arc breaking for efficient side-cutting of Ti2AlNb

This study introduces novel electrode-assisted hydrodynamic arc-breaking methods for the efficient side-cutting of Ti2AlNb, a material widely used in the aerospace industry but notorious for its machining difficulties. The research aims to overcome the limitations of traditional arc machining techniques, with a particular emphasis on deep-sidewall machining. The paper begins with an overview of electrode manufacturing processes used in electrode-assisted hydrodynamic arc-breaking methods. Following that, Fluent simulations are used to analyze particle behavior during the side-cutting process. The feasibility of these novel electrodes is then demonstrated using extensive single-factor experiments. The optimization of process parameters using orthogonal experiments, which significantly improves machining efficiency, is a crucial aspect of this study. The results showed that electrode-assisted arc breaking and hydrodynamic arc breaking for Ti2AlNb side-cutting processing increased the material removal rate by 65 % compared to conventional electrode materials, reduced relative electrode wear rate by 54 %, and reduced surface roughness by 85 %. Therefore, electrode-assisted hydrodynamic arc-breaking methods for side-cutting processing have a promising future in difficult-to-machine materials in the aerospace industry.

Experimental investigation of 3D taper profile machining of SS304 using WEDM

ABSTRACT Wire electrical discharge machining (WEDM) is an outstanding variety of EDM processes in which the tool is a wire electrode. The medical, electronics, tool, and die industries use stainless steel 304 (SS304). However, there are traditionally many complications that manufacturers face, while machining SS304. Also, the creation of 3D shapes using WEDM is challenging. Due to difficulties in normal machining and producing 3D profiles using conventional machining of SS304, this research aims to utilize the application of WEDM for creating complex shapes or products with top as square and bottom as rectangular shape to get a rectangular frustum. A ϕ 0.25 mm brass wire was used, and experiments were conducted as per L9 array. Further, the determination of the best process parameter (Ton, Toff, Voltage, current) combination for achieving the highest MRR, hardness, and minimal surface roughness (Ra) and kerf with analysis of machined surfaces using an SEM microstructure image was tried. The results indicated that MRR and Ra values varied from 7.05 to 47.29 mm3/min and 1.251 to 2.019 µm, respectively. Furthermore, the kerf ranged from 0.294 to 0.475 mm and hardness started at 164 to 233 HV. To optimize WEDM results Grey relational analysis (GRA) was utilized.

Machining SiC fibre reinforced metal matrix composites – How do different matrix materials affect the cutting performance?

SiC fibre reinforced metal matrix composites find widespread application but show major machining difficulties due to significant variations in constituents' properties. In this sense, while the SiC fibre plays significant strengthening effects, the properties mismatch between the brittle fibre and ductile matrix materials becomes important in their machining performance. Through machining tests, SiC fibre reinforced MMCs with Al (soft) and Ti (hard) matrix alloys are evaluated, showing the variation of interaction between inserts and fibres in cutting due to the different matrix properties. This leads to less tool wear but compromised surface integrity in Al-based composite than in Ti-based one.

Dry and Minimum Quantity Lubrication Machining of Additively Manufactured IN718 Produced via Laser Metal Deposition

Inconel 718 (IN718), a Ni-based superalloy, is immensely popular in the aerospace, nuclear, and chemical industries. In these industrial fields, IN718 parts fabricated using conventional and additive manufacturing routes require subsequent machining to meet the dimensional accuracy and surface quality requirements of practical applications. The machining of IN718 has been a prominent research topic for conventionally cast, wrought, and forged parts. However, very little attention has been given to the machinability of IN718 additively manufactured using laser metal deposition (LMD). This lack of research can lead to numerous issues derived from the assumption that the machining behavior corresponds to conventionally fabricated parts. To address this, our study comprehensively assesses the machinability of LMDed IN718 in dry and minimum quantity lubrication (MQL) cutting environments. Our main goal is to understand how LMD process variables and the cutting environment affect cutting forces, tool wear, surface quality, and energy consumption when working with LMDed IN718 walls. To achieve this, we deposited IN718 on SS309L substrates while varying the following LMD process parameters: laser power, powder feed rate, and scanning speed. The results unveil that machining the deposited wall closer to the substrate is significantly more difficult than away from the substrate, owing to the variance in hardness along the build direction. MQL greatly improves machining across all processing parameters regardless of the machining location along the build direction. Laser power is identified as the most influential parameter, along with the recommendation for a specific combination of power feed rate and scanning speed, providing practical guidelines for optimizing the machining process. While MQL positively impacts machinability, hourly energy consumption remains comparable to dry cutting. This work offers practical guidance for improving the machinability of LMDed IN718 walls and the successful adoption of LMD and the additive–subtractive machining chain. The outcomes of this work provide a significant and critical understanding of location-dependent machinability that can help develop targeted approaches to overcome machining difficulties associated with specific areas of the LMDed structure. The finding that MQL significantly improves machining across all processing parameters, particularly in the challenging bottom region, offers practical guidance for selecting optimal cutting conditions. The potential economic benefits of MQL in terms of tool longevity without a substantial increase in energy costs is also highlighted, which has implications for incorporating MQL in several advanced manufacturing processes.

A 330-GHz Radial Power Division/Combination Network Based on Circularly Polarized TE11 Mode

To compensate for severe mode interference and machining difficulties above the W-band of the traditional radial power combining scheme, a radial power division/combination network based on circularly polarized (CP) TE11 mode is designed. Firstly, the amplitude and phase distribution of the branches of a radial power divider under the excitation of CP mode are analyzed. The amplitudes of each branch are approximately equal, and the phase increases/decreases with equal differences. Therefore, a radial power divider with 16 branches based on a septum circular polarizer (SCP) is designed. An orthogonal cascade structure (OCS) and a parallel cascade structure (PCS) are proposed, and it is concluded that to obtain higher transmission efficiency, OCS and PCS should be used respectively when the phase or amplitude difference of SCP is worse. Finally, the power divider and a microstrip probe transition structure are cascaded back-to-back by using OCS, and the power division/combination network is obtained. Simulation results show that at 310-360 GHz, the amplitude difference of the branches of the power divider is less than ±0.35 dB; the combining efficiency of the power division/combination network is greater than 90%. This network has the advantages of single-mode operation, simple structure, and high combining efficiency. In addition, this article provides a feasible solution to the problem of depolarization loss caused by the cascade of SCPs.

Sustainability assessment and optimization for milling of compacted graphite iron using hybrid nanofluid assisted minimum quantity lubrication method

The climate change packages have strict regulations to reduce fuel consumption, costs, and carbon emissions in vehicles. Automobile manufacturers tend to utilize compacted graphite iron (CGI) in vehicle engine parts due to these regulations and rising engine performance needs. However, the difficulty of CGI machining and the sustainability problem during machining are barriers to its broad application in the automobile sector. In this study, nano molybdenum disulfide (nMoS2) reinforced nanofluid-assisted MQL (nMoS2-NMQL), multi-walled carbon nanotube (MWCNT) reinforced nanofluid-assisted MQL (MWCNT-NMQL) and nMoS2/MWCNT reinforced hybrid nanofluid-assisted MQL (HNMQL) cutting conditions were used for the first time in the milling of CGI material and machining performance was investigated in terms of cutting forces, cutting temperature and surface roughness. In addition, for the first time in the milling of CGI material, sustainability assessment and optimization in terms of carbon emissions and total machining cost have been carried out using non-dominant sequencing genetic algorithm II (NSGA-II) and technique for order of preference by similarity to ideal solution (TOPSIS). Using the MWCNT-NMQL cutting condition reduced the cutting temperature, resultant force, surface roughness, carbon emissions amount, and total machining cost by 38.2%, 54.5%, 57.6%, 7.6%, and 24%, respectively. The sustainability optimization conclusion was that MWCNT-NMQL cutting condition, cutting speed values between 90 and 93 m/min, and feed values between 0.11 and 0.117 mm/rev should be used in order to obtain the values closest to the optimum result for an improved and sustainable CGI milling process.

Design of dual-mode dual-band filter based on multilayer groove gap waveguide

This paper presents a novel dual-mode dual-band filter (DBF) based on multilayer groove gap waveguide (GGW). Unlike other published planar GGW filters, the proposed filter achieves a vertically stacked duplicate topology by introducing a rectangular aperture in the common wall and traditional inductive irises on the same layer, with perfect central symmetry in the overall structure. This reduces machining difficulty while having a smaller size. By optimizing the dimensions of the coupling structure and rectangular cavities, dual-mode resonators (DMRs) including even mode and odd mode are used to accomplish dual-bandpass response. Additionally, an efficient transition is presented and applied to achieve a good impedance matching from rectangular waveguide (RW) to GGW. To better demonstrate, a multilayer DBF with working center frequencies of 67.9 and 69.8 GHz is designed, fabricated and measured. Good consistency can be observed between the simulation result and the measurement result.

MC design and FIB preparation of a YSZ biochemical material microstructure

Aiming at the difficulty of traditional machining of Y2O3–ZrO2 (YSZ) inert ceramic materials, a different method using focused ion beam to selectively create nanoscale microscale structures on the surface of materials was proposed. The sputtering yield, surface damage, and the energy loss of YSZ materials was investigated using the SRIM software using the Monte Carlo method. It is shown that the sputtering yield increases with ion energy in the range 0–30 keV, reaching a maximum of 9.4 atoms/ion at 30 keV. At an ion beam voltage of 30 keV, the most severe damage to the material is 8 mm on the surface. At the same time, the main forms of energy loss in the treatment are phonon energy loss and ionization energy loss, of which phonon energy loss due to the recoil atoms is the largest. In addition, we continue to perform focused ion beam processing experiments on YSZ materials, combining previous MC modeling to optimize different operating conditions such as ion beam, voltage and processing mode. The optimized processing parameters are 30 keV and 2.5 nA. It is shown that the quality of the deep grooves gradually improves with decreasing ion beam current at the same ion beam voltage. However, an excessively small ion beam current leads to an excessively large depth of the deep grooves and lengthy processing times.

EFFECTS OF VIBRATION CONDITIONS ON MACHINABILITY OF AISI 52100 BEARING STEEL

This study focused on determining the effects of the cooling condition in the conventional and ultrasonic-assisted turning of AISI 52100 steel. AISI 52100 steel has been widely used in the bearing, mold, and automotive industries because of its superior wear resistance and mechanical properties. However, its high wear resistance caused poor machinability in conventional machining methods. Low surface quality, rapid tool wear, high cutting temperature, and high cutting force are the main difficulties in the conventional machining of AISI 52100 steel. On the other hand, ultrasonic-assisted machining has become widely used in the past decades for the machining of materials that have low machinability in conventional methods. Conventional turning and ultrasonic-assisted turning were selected as machining methods. Ultrasonic-assisted turning experiments were conducted under 20 and 30 kHz vibration frequencies. Cubic Boron Nitride (CBN) cutting tools were used in machining experiments. In machining operations 50, 100, and 150 m/min cutting speeds were selected, and feed rate (0.1 mm/rev) and depth of cut (0.5 mm) were kept constant in experiments. Minimum quantity lubrication technique which used 1% Al2O3 nanoparticle additives cutting fluid and dry cooling methods were used. CBN insert was used as a cutting tool. The effects of cutting speed, cutting method, and cooling condition on surface quality, cutting force, cutting zone temperature, and cutting tool wear were studied experimentally. Analysis of Variance (ANOVA) was carried out to determine the significance of the effects of input variables on process outputs. As a result of this study, it is determined that combined UAT and nanoMQL have significant effects on the process outputs.