Abstract
The present paper describes the effect of cutting and vibration parameters on the surface roughness of specimen machined by ultrasonic-assisted turning with self-lubricating cutting inserts. The selected process has been based on comparative analysis between conventional turning and ultrasonic-assisted turning using plane and textured cutting inserts. An improvement of the order of 35.89% is observed during ultrasonic-assisted turning with textured cutting insert as compared to conventional turning with plane tool. The latter part of the paper uses response surface methodology for performing the experimentation during ultrasonic-assisted turning with textured cutting insert. The experimental data have been analyzed using analysis of variance to highlight significant contributions of depth of cut, feed rate, cutting speed, and percentage intensity of ultrasonic power on surface roughness. The significant interactions among process parameters have also been analyzed to explain the possible alteration in the mechanism of material removal during ultrasonic-assisted turning using self-lubricating inserts. The best surface finish of the order of 0.431 µm has been found under optimal cutting and vibration parameters as evaluated by optimization of the developed statistical model using genetic algorithm.
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