Numerical investigation of hot ultrasonic assisted turning of aviation alloys

Aviation alloys exhibit superior properties such as high-strength-to-weight ratio and corrosion resistance but these alloys possess poor machinability. To overcome this disadvantage, new machining methods (Ultrasonic assisted machining, hot machining, etc.) are developed. Hot ultrasonic assisted turning (HUAT) is a new hybrid machining method which changes the cutting system between tool and workpiece, therefore, reduced cutting forces and better surface finish for workpiece are obtained. In this study, 2D finite element (FE) analysis is carried out to investigate the effects of these machining methods on titanium and Hastelloy-X alloys in terms of cutting forces, cutting tool temperatures and effective stresses. DEFORM-2D software is used during analyses. In addition, an experimental study is conducted to verify numerical results. During verification, cutting tool temperature is taken into consideration. It is confirmed that HUAT technique reduces cutting forces and effective stress significantly but cutting temperature increases compared to conventional and ultrasonic assisted turning.