An Experimental Study on the Cutting Forces, Surface Roughness and the Hardness of Al 6061 in 1D and 2D Ultrasonic Assisted Turning

Abstract:

The machinability of Al 6061 in 1D and 2D ultrasonic assisted turning (UAT) in terms of machining forces, surface roughness and hardness is investigated in this research. In order to perform the machining experiments, a 1D vibration tool and a 2D vibration tool are designed and manufactured. The cutting forces and surface roughness of the work-pieces in 1D UAT and 2D UAT are measured in different cutting speeds and feed rates and compared with that in conventional machining. To investigate the effect of the ultrasonic vibration on the material properties, hardness tests are performed on the work-piece material and micro-hardness tests are carried out on the chip specimens. The results showed that reduction in the cutting forces occurred in UAT. The results also showed that the surface roughness is exceled in UAT in comparison with the conventional machining. While no detectable effect of the ultrasonic vibration on the work-piece material could be observed, the chip micro-hardness experiments showed that the softening phenomenon occurred in UAT, which can be the cause of the force reduction in UAT.

• Periodical: Applied Mechanics and Materials (Volume 680)
• Pages: 224-227
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.680.224
• Online since: October 2014
• Authors: Reza Nosouhi*, Saeed Behbahani, Saeed Amini, Mohammad Reza Khosrojerdi
• Keywords: Al 6061, Cutting Force, Hardness, Surface Roughness (SR), Ultrasonic Assisted Turning

References

[1] Zhao Y, Zhang J, Shen X, Xing D (2011) Experimental Study on Surface Roughness by Ultrasonic Vibration Assisted Milling 2A12 Journal of Modular machine tools & automatic manufacturing technique, 01.

[2] Nategh MJ, Amini S, Soleimanimehr H (2009) Modeling the Force, Surface Roughness and Cutting Temperature in Ultrasonic Vibration-Assisted Turning of Al7075, Advanced Material Research, 83-86, pp.315-325.

DOI: 10.4028/www.scientific.net/amr.83-86.315

[3] Shen X, Zhang j, Li H, Wang J, Wang X (2012) Ultrasonic vibration-assisted milling of aluminum alloy The International Journal of Advanced Manufacturing Technology, Volume 63, Issue 1-4 , pp.41-49.

DOI: 10.1007/s00170-011-3882-5

[4] Syed Adnan A, Subbiah S (2010) Experimental investigation of transverse vibration-assisted orthogonal cutting of AL-2024, International Journal of machine tools and manufacture, 50, pp.294-302.

DOI: 10.1016/j.ijmachtools.2009.11.004

[5] Fan X, Miller MH (2001) Force Modeling in Vibration Assisted Cutting, Proceeding of the 2001 ASPE Annual Meeting, pp.92-97‏.

[6] Maurotto A, Muhammad R, Roy A, Babitsky VI, Silberschmidt VV (2012) Comparing Machinability of Ti-15-3-3-3 and Ni-625 Alloys in Uat. Procedia CIRP. Vol. 1, pp.330-335.

DOI: 10.1016/j.procir.2012.04.059

[7] Muhammad R, Maurotto A, Roy A, Silberschmidt VV (2012) Hot Ultrasonically Assisted Turning of B²-Ti Alloy. Procedia CIRP. Vol. 1, pp.336-341.

DOI: 10.1016/j.procir.2012.04.060