OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 5 4 3 The authors in [9] investigated the UVAT method for titanium alloy using dimensional analysis to study the effects of ultrasonic vibration parameters and conventional turning parameters on surface roughness and cutting forces, dimensionless groups were created. The dimensional analysis method was useful in optimizing the UVAT parameters for titanium alloy machining. Scientists in [10] presented dimensional analysis which was used in this work to investigate surface integrity during UVAT. The research examined how ultrasonic vibration parameters and conventional turning parameters affect surface roughness, residual stress, and micro hardness. The dimensional analysis method assisted in identifying the important parameters affecting surface integrity and gave guidance for enhancing surface quality using UVAT. Scientists in [11] proposed dimensional analysis which was used in this work to investigate surface integrity in UVAT of hardened AISI 4340 steel. Dimensionless groups were formed to investigate the effects of ultrasonic vibration and cutting modes on surface roughness, hardness, and residual stress. The study revealed the use of UVAT to improve surface integrity, as well as the utility of dimensional analysis in studying the process. The authors in [12] conducted an experiment which explained the dimensional analysis of ultrasonic vibration-assisted micro-cutting of silicon. Dimensionless groups were created to investigate the impact of ultrasonic vibration parameters and cutting parameters on cutting forces and surface quality. The dimensional analysis technique provided insights into the optimization of the silicon micro-cutting process. The purpose of this research paper is to comparatively evaluate the conventional hard turning and ultrasonic vibration-assisted hard turning and develop a theoretical model of tool wear and power consumption using dimensional analysis. The model will be developed using Buckingham Pi theorem considering cutting speed, density, workpiece hardness, vibrational amplitude, and frequency as the input parameters. The findings of this study will help to optimize the UVAHT of AISI 52100 steel, offering significant guidance for improving machining performance. Furthermore, the findings of the study will provide useful guidance for industry practitioners aimed at improving the efficiency and quality of hard turning operations on AISI 52100 steel employing ultrasonic vibration support. UVAHT has the potential to find widespread use in precision manufacturing sectors requiring hard and difficult-to-cut materials by expanding the understanding of this novel machining process. The methods of investigation UVAHT Equipment Configuration An ultrasonic vibration system is integrated with a conventional lathe in the experimental setup for ultrasonic vibration-assisted hard turning (UVAHT). A precision lathe with a motorized spindle and a modified tool holding fixture, specifically designed for mounting an ultrasonic vibratory tool (UVT), which is an assembly of a transducer, booster, and a horn that serves as a tool holder for performing hard turning operations conventionally and with ultrasonic vibration assistance. The rotating motion required by the workpiece and cutting tool is provided by the lathe. The total UVAHT composition is made up of several components such as a lathe machine, a workpiece, a specifically designed fixture, an ultrasonic frequency generator, and a transducer-booster assembly (fig. 1). In this sustainable cutting strategy, the cutting tool and w/p are regularly separated and get in contact (intermittent process), resulting in no BUE generation. This advanced technique consists of four major stages: 1) approach, 2) touch, 3) immersion, and 4) back off. These four steps of UVAT are recreated in fig. 2 for fully understanding this approach [13–15]. However, when vibrations are applied in the cutting velocity direction, a few limitations should be considered, namely Vc = πdn, Vt = 2πAF. Where “Vc” is cutting velocity, “n” is rotations per minute, “d” is workpiece diameter, “Vt” is tip velocity, i.e. vibrational speed of cutting, “A” is vibration amplitude, and “F” is frequency. If A = 20 m and F = 20 kHz, then the value for “Vt”, i.e., the tip velocity, should be less than 150 m/min. The relative displacements of the cutting tool and the workpiece in ultrasonic-assisted turning (UVAT) are depicted in fig. 3 [16].
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