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In recent years, there have been many modern engineering materials introduced recently which are hard, brittle and difficult to machine. These materials are very difficult to machine with conventional turning methods. Ultrasonic assisted turning (UAT) is a new non-conventional technique, used to remove an unwanted material to produce a desired prod...
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... The ultrasonic vibration-assisted cutting can be classified into one dimensional (1D), 26,[34][35][36][37][38] two dimensional (2D), [39][40][41][42][43][44][45] and three dimensional (3D) ultrasonic vibration-assisted cutting based on the vibrations applied in different directions. [46][47][48][49] The vibration assisted machining was introduced in 1960s, and in 1980s and 1990s different vibration modes were developed for vibration assisted machining. ...
... Fig. 4 depicts different types of vibration modes in UVAM and UVAT. 26,[34][35][36][37][38][39][40][41][42][43][44][45][46][47][48][49] Lin et al. 56 developed a 3D elliptical vibration system to perform 3D UVAT by using the diamond tool. 3D elliptical vibrations applied on the tool enhanced the tool life and improved the machined surface quality. ...
... Different vibration modes in UVAM and UVAT. 26,[34][35][36][37][38][39][40][41][42][43][44][45][46][47][48][49] In summary, the analysis of previous literature indicated that a low value of TWCR is beneficial for vibration-assisted machining to obtain good machining performance. Compared to CM, the decrease in TWCR in UVAM signifies a reduction in cutting time, ultimately resulting in a decrease in cutting forces, increased heat dissipation, enhanced surface quality, and improved tool life. ...
... In the existing literature and visible documents, there are few studies on the UAT of the 304 austenitic stainless steel, and especially the research on tool wear is limited extremely. Vivekananda et al. [27,28] designed and analyzed the ultrasonic vibrating tool and carried out the UAT and CT experiments for the 304 stainless steel under different cutting conditions. The results suggested that the UAT was suitable for generic engineering materials and could achieve higher quality surface finish and lower cutting force than the CT. ...
The 304 austenitic stainless steel is used in a wide range of important industries such as industrial, food, medical, and furniture decoration, seeming the most widely used chromium-nickel stainless steel, but which machinability proves very poor, being a typical difficult cutting material. The tool wear phenomenon is very serious in the process of cutting and is not easy to acquire the splendid machining quality. For this reason, the ultrasonic vibration is introduced into turning to realize ultrasonic vibration-assisted turning (UAT) to solve the above problems in this study. This paper first proves that the ultrasonic vibration has a certain inhibitory effect on the tool wear by theoretical and simulation methods. Then, the influence of technological parameters on the tool wear is studied by experiments. The results show that there is an optimal range of the ultrasonic amplitude and the cutting speed for the UAT, and which has a significant inhibitory effect on the tool wear when the technological parameters are selected properly. The tool wear of conventional turning (CT) is more serious under the same technological parameters. In addition to the abrasive wear and the adhesive wear, the deformation and the collapse also occur, accompanied by obvious sticking substances, which reduce the service life of the cutting tool greatly and has a certain impact on the machining efficiency and the cost. Furthermore, the UAT can also achieve better-machined surface quality under the condition of technological parameters with the less tool wear.
... The process parameter optimization of ECDM is not considered by Goud et al. [6]. Table 2 presents the applications of various optimization techniques used for the parameter optimization of various non-traditional machining processes for single-objective and multi-objective optimization [7,8,9,10,11,12,13,14,15,16,17,18,19,20,21,22,23,24,25,26,27,28,29,30,31,32,33,34,35,36,37,38,39,40,41,42,43,44,45,46,47,48,49,50,51,52,53,54,55,56,57,58,59,60,61,62,63,64,65,66,67,68,69,70,71,72,73,74,75,76,77,78,79,80,81,82,83,84,85,86,87,88,89,90,91,92,93,94,95,96,97,98,99,100,101,102]. Furthermore, Table 3 presents the advantages and disadvantages of various advanced optimization techniques which will be helpful in selecting the appropriate optimization technique for the research work of future researchers and industrialists. ...
... With the USM process, various modified forms of USM process like Ultrasonic Drilling (USD) [40,41], Micro-Ultrasonic Drilling (Micro-USD) [37], Rotary Ultrasonic Drilling (Rotary-USD) [38,42], and Vibration Assisted Ultrasonic Turning (VA-UST) [35] are used for a specific purpose. Different types of materials which are commonly machined using the USM process are glass, aluminum, tungsten carbide, ceramics, and various types of composite materials. ...
... In this research work, after parametric optimization, energy consumption is reduced to 33% of the whole energy consumption. Vivekanand et al. [35] did the process parameter optimization of VA-UST by considering the minimization of SR and cutting forces developed during the process. In this research, results show that there is a decrease in SR by 12% to 40% and cutting forces by 25% to 35% compared to conventional turning. ...
div>A comprehensive literature review of the optimization techniques used for the process parameter optimization of Abrasive Jet Machining (AJM), Ultrasonic Machining (USM), Laser Beam Machining (LBM), Electrochemical Machining (ECM), and Plasma Arc Machining (PAM) are presented in this review article. This review article is an extension of the review work carried out by previous researchers for the process parameter optimization of non-traditional machining processes using various advanced optimization algorithms. The review period considered for the same is from 2012 to 2022. The prime motive of this review article is to find out the sanguine effects of various optimization techniques used for the optimization of various considered objectives of selected non-traditional machining processes in addition to deemed materials and foremost process parameters. It is found that most of the researchers have more inclination towards the minimization of Surface Roughness (SR) compared to the maximization of the Material Removal Rate (MRR) as their objective function for AJM and PAM. Similarly, for USM and ECM, researchers are more inclined towards the maximization of MRR compared to the minimization of SR. Minimization of the Heat-Affected Zone (HAZ) and SR are the two most considered response parameters for the LBM and its allied processes. This study provides ready-to-use details on the use of various advanced optimization techniques for AJM, USM, LBM, ECM, and PAM, with the considered workpiece material, process parameters, and imposed limitations. This review work is carried out on such a large scale that it will help future researchers and industrialists to decide their research direction.</div
... Nevertheless, with continuously emerge and use of multitudinous precision instruments and parts requirements of machining accuracy and machining quality are more demanding than ever before [5][6][7]. In the meantime, in the field of machinery manufacturing, the diversified difficult-to-cut materials (DCM) are increasingly widely used and the number of turning processing increases, so that the difficulty of turning processing continues to enhance [8,9]. For the CT process, due to accompanying with the large cutting temperature and cutting force, the difficult chip breaking and chip removal, the severe tool wear and other serious problems in the course of turning, the processing quality becomes poor and the processing efficiency decreases, likewise, the processing cost also aggrandizes [10,11]. ...
The 5A06 Al-Mg alloy is a soft material, and the phenomenon of knife sticking is extremely serious during cutting, likewise, it is easy to generate build-up edges. Therefore, it is difficult to acquire good surface quality in turning. For this purpose, the ultrasonic theory and cutting theory are fully combined in this study, and the machining mechanism of conventional turning (CT) is changed by applying ultrasonic vibration (UV) to the cutting tool, so as to build up the machining results. The turning experiments of 5A06 Al-Mg alloy with or without UV are carried out under different process parameters, and through which the effects of ultrasonic amplitude (UA), feed rate (FR), cutting depth (CD) and cutting speed (CS) on the surface roughness of machined workpiece are investigated and analyzed. The consequences show that the process parameters have a different degree of effect on surface roughness. And there are special process parameters suitable for UV assisted turning (UAT), under which the processing results of UAT is obviously better than that of CT. In addition, it is found that by contrast experiment of surface topography under ideal process parameters built-up edges, surface scratches and other phenomena are not easy to arise in UAT to obtain the better surface topography than CT.
... This case has led researchers to seek new ways. On the other hand, the application area of materials that have difficult to cut by using traditional machining methods is to increase [1]. The ultrasonic-assisted turning (UAT) method has been widely used in machining difficult-to-cut materials in recent years, as it exhibits better surface quality, lower cutting forces, and cutting zone temperature than the conventional turning (CT) methods. ...
High cutting force and high cutting tool-chip interface temperature occur during machining of high
strength materials like AISI 52100 by using conventional turning method and this makes to the
difficult machining operation. Besides, in conventional turning (CT) of these materials, which has
high abrasion resistance and hardness properties, an additional process such as grinding is required to
achieve the desired surface quality. Ultrasonic assisted turning (UAT) method has been widely used in
the machining industry in recent years, as it exhibits better surface quality, lower cutting forces, and
cutting temperature than the CT method. This paper focused on experimentally and statistically
determining the effects of different cutting parameters and cooling conditions (dry and minimum
quantity lubrication-MQL) on surface roughness, workpiece surface texture, tangential direction
cutting force, and cutting tool-workpiece interface temperature in the machining of AISI 52100
material by using UATand CT methods. The experimental results revealed that significant
improvements determined in the cutting forces and the surface roughness occurred inUATcompared
to CTin all the cooling conditions. However, the increasing cutting speeds caused to observe higher
interface temperature values in dry turning by the UATmethod. Variance Analysis (ANOVA) was
carried out to determine the significance grade of independent variables on dependent variables.
According toANOVAresults, while the cutting speed is the most important factor on the surface
roughness and the cutting zone temperature, and the cooling method is the most important factor on
the cutting force. The effects of turning methods on corresponding surface topography, including
surface defects, were evaluated. It is determined that in the surface topography analysis, feed marks are
the main texture of the workpiece in the CTmethod while micro-level indentations and protrusions
occurred on the workpiece surface in theUAT method.
... Non-conventional technologies have been designed, developed, and used during SPDT procedure for assisting the cutting process and improving the machining condition. In the hybrid SPDT platforms, beside the assisting techniques, on-machine metrology systems (OMMS) have been developed and used for measuring, testing, and diagnosing the machined profiles, as well as investigating the effect of the process parameters and machining conditions on the outcome of the diamond cutting process [11][12][13][14][15][16][17][18][19][20][21][22][23][24]. ...
Single-point diamond turning (SPDT) is a machining process with high levels of profile accuracy and nanometric surface characteristics. SPDT is a leading technology in advanced manufacturing of ultra-precision optical components for critical applications. Different efforts have been undertaken to improve the cutting condition and optimize the machining parameters during SPDT. The implementation of on-machine metrology system (OMMS) has helped to improve the outcomes of SPDT in terms of machined profile accuracy and understand the effects of various processing parameters on optical surface generation. OMMS could be implemented in the hybrid SPDT platforms to effectively improve machining conditions by measuring and diagnosing, and providing testing procedures. Different sensors and principles have been used in the design and development of OMMS including laser-based optical systems. However, measuring the micrometric and nanometric parameters during diamond cutting is difficult to achieve at relatively low resolutions. The purpose of this study is to design and simulate an electro-optical vibrometer (EOV) for measuring machine-tool and workpiece vibration during the SPDT process. The proposed EOV has the capability of measuring, monitoring, and analyzing the vibration characteristics in different machining conditions. In addition, the designed system can communicate with the main control units of the hybrid SPDT platforms. Design specifications and simulation results have shown that the implemented mechanism is functional and has met requirements for a successful profiling vibrometry system that can be employed on SPDT machines.
... They reported that the TOPSIS approach accurately ranked the alternatives. Vivekananda et al. [13] used FEA and TOP-SIS to optimized process parameters of the vibration-assisted turning process. EDAS or evaluation based on distance from average solution is an MCDM that calculates the distance of each alternative from the average solution and uses this information to select the best alternative. ...
Brake discs are crucial part of any automobile, since they provide frictional effect for braking. They should be reliable and have long functional life. In this regard, both the fatigue life of the brake disc and its ability to resist axial deflection is important. In this research, a finite element model for a ventilated brake disc is developed to numerically simulate the fatigue life and axial deflection. The effective performance of the brake disc is analysed using a two-level full factorial design based on five different design parameters, namely inboard plate thickness, outboard plate thickness, vane height, effective offset and centre hole radius. To analyse and compare the various design parameter combinations, multi-criteria decision-making (MCDM) is used. A comprehensive comparative study for determination of design parameters is carried out by using four different MCDM methods. It is found that the optimal predictions of the four MCDMs used in the study have a high correlation. Furthermore, based on the research, a higher-level setting of all the five design variables is found to be most suitable. However, all the other four design variables except inboard plate thickness are found to have a low influence on the multi-criteria brake performance.
... Mode I and Mode II fracture energy can be calculated by experimentally measured fracture toughness (K IC and K IIC ) as [38]: ...
This research work presents a numerical study of the orthogonal cutting process employing a finite element approach to optimize dry machining of aluminium alloy 2024. The main objective of the research work is to perform three-dimensional finite element simulations for a better understanding of temperature distribution and residual stresses development in the workpiece and tool regions along depth of cut direction. While, two dimensional models don’t predict true picture of aforesaid parameters along cutting depth due to material’s out of plane flow and deformation. In the present study, effects of tool rake angles (7°, 14°, 21°) and cutting speeds (200, 400, 800 m/min) upon variations in chip geometry at various sections along workpiece width (depth of cut) have been discussed at large. Furthermore, cutting forces and tool-workpiece temperature profiles are also in depth analysed. The findings will lead the manufacturers to better decide post machining processes like heat treatment, deburring, surface treatments, etc. The results showed that a combination of a rake angle of 14° at cutting velocity of 800 m/min produces serrated chip segments with relatively moderate cutting forces in comparison to other parametric combinations. The efficacy of the presented finite element model is verified by comparing the numerically obtained results with experimental ones.
... (6)(7)(8)(9)(10) Concerning the investigation of the machine structure of tool machinery, many studies on the stiffness of machine tools using experimental, analytical, or numerical methods have been carried out. (11)(12)(13) Specifically, Vivekananda et al. (14) used ANSYS software to obtain the natural frequency of vibration for ultrasonic turning in the machining process. Hong et al. (15) investigated the static structure of the five-axis turning-milling complex CNC machine using the SOLIDWORKS CAE software technique. ...
... Although setting optimum machining parameters and providing an optimized machining condition could reduce the effects of mentioned influencing factors while improving the quality of turned product, these improvements could not satisfactorily solve limitations. Material removal rate, productivity, high cost, and machining quality are main limitations, especially in turning brittle and difficult to cut materials [147,[214][215][216][217][218][219][220]. Finally, it could be concluded that many factors may directly/indirectly influence and limit optical surface generation and the quality of finished product. ...
Ultra-precision machining is the recent realm subsequent to conventional precision machining processes. Recently, achieving nanoscale features on products has become important in manufacturing of critical components. One of the main objectives in advanced manufacturing of optics is to reach ultimately high precision in accuracy of optical surface generation. Through further development of computer numerical controlled machinery technology, single-point diamond turning (SPDT) has evolved rapidly and became a key step in the process chain of nano-machining. In SPDT, advanced and competitive technology for optical surface generation combined with ultra-precision fixtures and accurate metrological systems, high-precision surface machining with scales down to 1 nanometer, even less than 1 nanometer, are successfully achieved. Different engineering applications including medical, dental, defense, aerospace, computer science, and electronic components demand extreme smoothness and optical quality of the machined surfaces. However, there are limitations and drawbacks in SPDT process and surface generation using this technology. Different factors may significantly influence turning conditions, affect surface generation, and limit the outcome of the process. This paper attempts to provide a review of ultra-precision SPDT: technology and characteristics, manufacturing process, applications, machinable materials, and surface generation. Subsequently, influencing factors on surface generation are introduced and comprehensively discussed. Studying influencing factors on surface generation could enable setting optimized sets of machining factors and providing best possible machining conditions for generating high quality optical surfaces. Furthermore, limitations and drawbacks of standard structure SPDT process is discussed. Although a number of published studies have attempted to provide a good perspective of the SPDT process by looking into the effect of influencing factors on surface generation and existing limitations, more investigation needs to be undertaken to discover all destructive effects, origins, and influences in order to further extend the machinability of materials, reduce side effects, and improve the outcome of SPDT.
