Effect of Compressed Air Cooling on Tool Wear During Ultrasonic-Vibration-Laser Assisted Turning of Aluminium Alloy

IntroductionThe utilization of various energy sources to assist the machining process has become prominent to achieve substantial improvement in machining performance. These energy sources have also resulted in an alternative to cutting fluids which is safer for both the universe and human beings. The combined action of laser and ultrasonic vibration energies during the turning process has shown significant achievement in machining process capabilities. Moreover, the application of higher compressed air pressure has achieved substantial improvement in machinability during the turning process.Materials and methodsAn attempt has been made to improve the machinability of aluminium 3003 alloy during the simultaneous application of compressed air pressure and ultrasonic-vibration-laser-assisted turning (UVLAT) process. Machining performance has been analyzed in terms of machining temperature, tool wear, machining forces, chip morphology, and surface roughness. A comparative machining performance analysis has been carried out between different compressed air pressure for the laser-assisted turning (LAT) and UVLAT processes.ResultsThe outcomes of the current study indicate a significant reduction in maximum machining temperature due to higher compressed air pressure. Lower tool wear was observed due to a reduction in maximum machining temperature and led to lower machining forces at higher compressed air pressure. Lesser chip segmentation and smooth chip edges were obtained which led to a reduction in surface roughness for higher compressed air pressure during the LAT and UVLAT processes.ConclusionThe presented results are important for manufacturing industries seeking to improve the machinability of aluminium alloys.

Automated summary

The combined action of laser and ultrasonic vibration energies has shown significant achievement in machining performance. Higher compressed air pressure has achieved substantial improvement in machinability. The outcomes of the current study indicate a reduction in maximum machining temperature, lower tool wear, reduced machining forces, and improved surface roughness at higher compressed air pressure during the processes.