Hybrid turning process by interacting ultrasonic vibration and laser energies

Abstract

Hybrid machining processes are developed to achieve enhanced machining performance for various materials. In this study, ultrasonic vibration and laser sources interact simultaneously during the hybrid turning process and the process is termed ultrasonic vibration laser-assisted turning (UVLAT). Ultrasonic vibration-assisted turning (UVAT) fixture is mounted along with laser assisted turning (LAT) fixture on the lathe machine during the developed hybrid process. An experimental investigation on aluminum 3003 alloy is performed to analyze the machining performance for conventional turning (CT), UVAT, LAT, and UVLAT. Cutting speed and laser power are varied to machine aluminum alloy during various processes. The investigation shows that lower machining forces, higher machining temperature, smooth and lesser segmented chips, and lower surface roughness are obtained during UVLAT in comparison to CT, UVAT, and LAT. At higher cutting speed, machining forces and surface roughness are increased and decreased at higher laser power, whereas vice versa to machining temperature with variation in speed and power. Smooth edges and less segmentation are observed at higher laser power and cutting speed. Outcomes suggest that the machining performance of aluminum alloy is enhanced during the UVLAT process when compared with other processes.