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

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.