OBRABOTKAMETALLOV Vol. 25 No. 4 2023 149 EQUIPMENT. INSTRUMENTS Ultrasonic vibration-assisted hard turning of AISI 52100 steel: comparative evaluation and modeling using dimensional analysis Govind Ghule1, a,*, Sudarshan Sanap1, b, Satish Chinchanikar2, c 1 MIT-School of Engineering, MIT-ADT University, Pune - 412201, India 2 Vishwakarma Institute of Information Technology, Pune - 411048, India a https://orcid.org/0000-0003-4331-3501, govindghulemasterofengineering@gmail.com; b https://orcid.org/0000-0002-3788-0692, sudarshan.sanap@mituniversity.edu.in; c https://orcid.org/0000-0002-4175-3098, satish.chinchanikar@viit.ac.in Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2023 vol. 25 no. 4 pp. 136–150 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2023-25.4-136-150 ART I CLE I NFO Article history: Received: 03 September 2023 Revised: 17 September 2023 Accepted: 27 September 2023 Available online: 15 December 2023 Keywords: Ultrasonic vibrations Hard turning Dimensional analysis Buckingham Pi theorem Tool wear Power consumption ABSTRACT Introduction. Precision machining of hard and brittle materials is diffi cult, which has led to the development of novel and sustainable techniques such as ultrasonic vibration-assisted turning (UVAT) for enhanced removal rates, surface quality, and tool life. The purpose of the work. Hard turning using cost-eff ective coated carbide tools instead of costly to operate ceramic and CBN inserts is still not widely accepted due to tool wear and machining limitations. A group of researchers attempted hard turning using carbide tools with diff erent coatings, diff erent cooling techniques, etc., to achieve better machinability. However, very few attempts were made by the researchers on ultrasonic vibration-assisted hard turning (UVAHT). Moreover, comparative evaluation of UVAHT using dimensional analysis is rarely reported in the open literature. The methods of investigation. With this view, this study comparatively evaluates the tool wear and power consumption during conventional turning (CT) and ultrasonic vibration-assisted hard turning (UVAHT) of AISI 52100 steel (62 HRC) using a PVD-coated TiAlSiN carbide tool. Experiments were performed with varying cutting speed, feed, and depth of cut while keeping vibration frequency and amplitude constant at 20 kHz and 20 μm, respectively. Further, a theoretical model was developed to predict the tool wear and power consumption using the concept of Dimensional analysis, i.e., the Buckingham Pi theorem considering the eff ect of cutting speed, frequency, and amplitude of vibrations at constant feed and depth of cut of 0.085 mm/rev and 0.4 mm, respectively. Dimensionless groups were created to reveal complex linkages and optimize machining conditions. Tool wear and power consumption were measured experimentally and statistically analyzed using the Buckingham Pi theorem. Results and Discussion. Using dimensional analysis, the research uncovers substantial insights into the UVAHT process. The results show that ultrasonic vibration parameters have a signifi cant impact on tool wear and power consumption. Dimensionless groups provide a methodical foundation for refi ning machining conditions. The tool wear and the power consumption increase with the cutting speed, depth of cut, and feed. However, this eff ect is more signifi cant in CT than UVAHT. The power consumption increases with the cutting speed, vibration frequency, and amplitude. However, the increase in the power consumption is more prominent when the cutting speed changes, followed by vibration frequency and amplitude. The fl ank wear increases with the cutting speed and vibration amplitude and decreases with the vibration frequency. This study contributes to a better understanding of the underlying dynamics of UVAHT, which will help to improve precision machining procedures for hard materials. The paper explores the practical signifi cance of these discoveries for hard material precision machining. For citation: Ghule G.S., Sanap S., Chinchanikar S. Ultrasonic vibration-assisted hard turning of AISI 52100 steel: comparative evaluation and modeling using dimensional analysis. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2023, vol. 25, no. 4, pp. 136–150. DOI: 10.17212/1994-6309-2023-25.4-136-150. (In Russian). ______ * Corresponding author Ghule Govind S., M.E. (Design Engineering), Assistant Professor MIT-School of Engineering, MIT-ADT University, Pune - 412201, India Tel.: +91-7020742258, E-mail: govindghulemasterofengineering@gmail.com References 1. Babitsky V.I., Kalashnikov A.N., Meadows A., Wijesundara A.A.H.P. Ultrasonically assisted turning of aviation materials. Journal of Materials Processing Technology, 2003, vol. 132, pp. 157–167. DOI: 10.1016/s09240136(02)00844-0.
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