Experimental study on the ultrasonic assisted face turning residual stress

The Experimental study investigates the impact of ultrasonic-assisted face turning (UAFT) on cutting forces, tensile residual stress, and surface topography. The primary objective is to identify optimal cutting parameters that yield a smoother surface finish while concurrently reducing cutting forces and tensile residual stress. The tests were conducted on a lathe machine equipped with ultrasonic assistance, using 1.7225 steel as the workpiece material. Various cutting parameters, including feed rate, spindle speed, and turning state, were varied. The results illuminate the significant efficacy of ultrasonic assisted face turn (UAFT) in improving surface topography, compared to conventional turning (CT). The optimal turning parameters for achieving the smoothest surface finish were determined to be a higher spindle speed and lower feed rate. Moreover, the introduction of ultrasonic vibration led to a substantial reduction in cutting forces, primarily attributable to the diminished attrition between the cutting tool insert and the work part. Overall, the experimental study demonstrates the effectiveness of ultrasonic-assisted face turning in enhancing surface topography, with an improvement of approximately 39%. Additionally, the study demonstrated a reduction in cutting forces by approximately 50% and a decrease in tensile residual stress by approximately 33.8%. These findings underscore the potential of ultrasonic vibration as a tool for optimizing cutting parameters to achieve desired surface finishes in machining applications.