Experimental investigation on hybrid turning of aluminum alloy using ultrasonic vibration and laser energy

Usage of cutting fluids during the machining of aluminum alloys enhances production costs and creates an unhealthy environment for nature and the operator. In the present work, ultrasonic vibration and laser energies are interacted with during the turning process simultaneously, and the process is termed ultrasonic-vibration-laser-assisted turning (UVLAT). Experiments are performed on aluminum alloy to compare the machinability among UVLAT, conventional turning (CT), ultrasonic vibration-assisted turning (UVAT) and laser-assisted turning (LAT). Outcomes revealed that low machining forces and low surface roughness are obtained for UVLAT compared with CT, UVAT and LAT. Diffusion and abrasive wear are observed during UVLAT, while adhesion and abrasive wear are observed during CT, UVAT and LAT. EDS analysis showed the adhesion of aluminum alloy on the tool face. Smooth edges, negligible chip segmentation and thin continuous chips are observed in UVLAT and UVAT, whereas thick continuous chips are observed in CT and LAT. The results showed that the machinability of aluminum alloys is enhanced in terms of reduced machining forces, lower tool wear, thin and negligible chip generation and lower surface roughness during UVLAT compared to the CT, UVAT and LAT processes.