Tool-Work Contact Ratio and Parametric Influence in Ultrasonic Vibration–Assisted Turning of Ti6Al4V Alloy

Abstract

ABSTRACT The performance of the machining process depends on the time of contact of the cutting tool with the workpiece. In this work, the effect of vibrating and cutting parameters on tool-work contact ratio (TWCR) in ultrasonic vibration–assisted turning (UVAT) is evaluated. Machining performance is measured in terms of average cutting force, cutting temperature, and average surface roughness. Full factorial experiments are conducted on a Ti6Al4V alloy to evaluate the performance of the UVAT process in terms of TWCR. The performance of the UVAT process is analyzed and compared with the conventional turning process at various conditions, such as intensity of ultrasonic power (80, 90, and 100 %), cutting speed (10, 30, and 50 m/min), feed rate (0.055, 0.103, and 0.161 mm/rev), and depth of cut (0.1, 0.3, and 0.5 mm). The cutting force, cutting temperature, and surface roughness are decreased with the increase in percentage intensity of ultrasonic power. The effectiveness of UVAT process is greater at higher levels of vibrating parameters and lower levels of cutting parameters in the selected range. Finally, it is concluded that the maximum benefit from the UVAT process is obtained at TWCR of 0.136 and its effect is dominant at lower levels of cutting conditions. However, the effect of thermal loading is dominant at higher levels of cutting conditions in the selected range.