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A Machining Force Model Developed for Ultrasonic Vibration-assisted Turning, through Statistical Analysis of Influential Parameters

A machining force model for ultrasonic vibration-assisted turning (UAT) has been developed in the present study. For this purpose, extensive full-factorial experiments were carried out and the results were analyzed statistically. Various influential parameters, such as cutting speed, feed rate, depth of cut, and ultrasonic vibration amplitude were taken into account. The proposed model was selected from among four different regression models. The condition for the robustness of the proposed model was then investigated. Several experiments were also carried out on conventional turning and the results were analyzed and compared with those obtained during ultrasonic vibration-assisted turning. It was shown that the quadratic polynomial model can better estimate the machining force. The latter experiment with a vibrating tool is unconditional and considerably lower than that created in conventional turning. The continuous chip being formed in UAT is partially responsible for more efficient machining (from the view point of ductile regime of machining) compared to conventional turning (CT).