OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 5 No. 4 2023 Introduction Ultrasonic vibration-assisted hard turning (UVAHT) is a potential machining technique that combines the advantages of traditional turning with the use of ultrasonic vibrations to improve hard material machining. AISI 52100 steel is a commonly used bearing steel that is noted for its excellent hardness, wear resistance, and dimensional stability. Ultrasonic vibration-assisted turning (UVAT) has demonstrated tremendous potential for improving the machinability of such hard materials, allowing for higher material removal rates, enhanced surface integrity, and reduced tool wear [1–3]. Because of its high strength and hardness, the typical hard turning method sometimes finds difficulties when machining hardened materials such as AISI 52100 steel. This results in increased cutting forces, higher tool-workpiece interface temperatures, and accelerated tool wear, all of which impair the surface polish and dimensional accuracy of the machined components. UVAHT can alleviate these issues and provide various benefits by adding high-frequency ultrasonic vibrations during the turning process. The underlying dynamics of UVAHT involve the propagation of ultrasonic vibrations through the tool and into the workpiece, which results in micro fracturing, lower cutting forces, and enhanced chip removal. These dynamic impacts on the cutting process change the material removal mechanism and affect the toolworkpiece relationship, resulting in better cutting performance. However, to take full advantage of UVAHT of AISI 52100 steel, it is necessary to understand the impact of numerous process factors and its interactions. Ultrasonic vibration-assisted hard turning (UVAHT) has received a lot of attention in recent years as a potential machining technology for hard materials such as AISI 52100 steel. Several studies have investigated the impact of ultrasonic vibration on hard turning operations and its potential advantages for increasing surface integrity, reducing cutting forces, and extending tool life. The literature study provided here gives an overview of significant research related to UVAT and its use in the machining of AISI 52100 steel. The use of ultrasonic vibrations in machining operations has received a lot of attention. Some studies have focused on ultrasonic-assisted turning of conventional materials, emphasizing the reduced cutting forces and increased surface polish attained with this technology. Liu et al. [4] studied the impact of ultrasonic vibration on the cutting performance of AISI 1045 steel and found that it improved tool life and surface quality significantly. These investigations laid the groundwork for further research into the use of UVAHT for hard materials such as AISI 52100 steel. Because of its numerous industrial uses, hard turning of AISI 52100 steel has piqued interest. To improve the machinability of this material, researchers investigated various cutting modes and tool geometries. The authors in [5], for example, investigated the effect of cutting speed and feed rate on tool wear and surface roughness during hard turning of AISI 52100 steel. These studies revealed the difficulties associated with traditional hard turning and stimulated the study of other methods such as UVAHT. The use of ultrasonic vibrations in hard turning has showed significant promise in terms of enhancing machining performance. The effects of various ultrasonic parameters, such as vibration amplitude and frequency, on cutting forces and surface integrity during UVAHT have been studied. In [6] investigated the impact of ultrasonic vibration amplitude on chip formation and surface roughness during hard turning of AISI 4140 steel, offering important insight into the dynamic effects of ultrasonic vibrations on material removal. In the field of machining, dimensional analysis has been widely employed to investigate the correlations between process parameters and performance indicators. The authors in [7] used dimensional analysis to study the effect of cutting modes on surface roughness in hard turning, laying the groundwork for applying this method to UVAHT. Similarly, Zhang et al. [8] used dimensional analysis to investigate the impacts of process parameters in ultrasonic vibration-assisted milling, emphasizing its use for optimizing machining processes. Dimensional analysis is a strong method for studying the UVAHT process and identifying the important characteristics that affect its success. This method entails identifying and formulating dimensionless groups that connect the important process variables without necessitating entire experimental research. Dimensional analysis gives important insights into the interactions between numerous process factors and its impact on cutting performance by reducing complicated relationships to dimensionless parameters.
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