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Experimental and analytical study of ultrasonic elliptical vibration cutting on AISI 1045 for sustainable machining of round-shaped microgroove pattern

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Abstract

This research report deals with an experimental and analytical study of the ultrasonic elliptical vibration cutting (UEVC) process on medium steel alloy (AISI 1045) for sustainable machining of round-shaped (R-shaped) microgrooves via relatively low-speed machining (0.5–2.5 m/min). The need for microgroove patterns on planar surfaces in the tribology field has increased significantly owing to superior lubrication performance in decreasing the coefficient of friction. Analyzing the surface roughness, microgroove morphology, cutting force, and chip formation during microgrooving are the main objectives of this experimental study. The experimental results showed that the UEVC process evidently produces lower surface roughness, lower cutting forces, better groove shape morphology, thinner chip thickness, and higher flow shear angle when compared to the conventional cutting process. A new approach in methods to analyze surface roughness and cutting force in UEVC microgrooving has also been developed and validated with the experimental results. Finally, these experimental studies indicate the achievement of sustainable machining of the R-shaped microgroove pattern using the UEVC process.

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Acknowledgements

This research was supported by Basic Science Research Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Science, ICT and Future Planning (grant number NRF-2017R1A2B2003932). Also, this work was supported by the 2017 Yeungnam University Research Grant. This work has been also supported by the Basic Science Research Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Education (NRF-2017R1A4A1015581).

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Authors and Affiliations

  1. School of Mechanical Engineering, Yeungnam University, 214-1, Dae-dong, Gyeongsan-si, Gyeongsangbuk-do, 712-749, South Korea

    Rendi Kurniawan, Saood Ali & Tae Jo Ko

  2. Faculty of Mechanical Engineering, Kalasalingam University, Krishnankoil, Tamil Nadu, 626126, India

    S. Thirumalai Kumaran

  3. School of Materials Science and Engineering, Yeungnam University, Gyeongsan, 38541, South Korea

    Dwi Ayu Nurcahyaningsih

  4. School of Mechanical Engineering, Universitas Indonesia, Kampus Baru UI, Depok, 16424, Indonesia

    Gandjar Kiswanto

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  1. Rendi Kurniawan
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  2. S. Thirumalai Kumaran
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  3. Saood Ali
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  4. Dwi Ayu Nurcahyaningsih
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  5. Gandjar Kiswanto
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  6. Tae Jo Ko
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Correspondence to Tae Jo Ko.

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Kurniawan, R., Kumaran, S.T., Ali, S. et al. Experimental and analytical study of ultrasonic elliptical vibration cutting on AISI 1045 for sustainable machining of round-shaped microgroove pattern. Int J Adv Manuf Technol 98, 2031–2055 (2018). https://doi.org/10.1007/s00170-018-2359-1

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