Original article

Proc IMechE Part E:

J Process Mechanical Engineering
FE simulation of linear and elliptical 0(0) 1–11
! IMechE 2017

ultrasonic vibrations in turning of Reprints and permissions:

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Inconel 718 DOI: 10.1177/0954408917715533

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Mohammad Lotfi and Saeid Amini

Abstract
Utilization of ultrasonic vibrations in turning operation is an advanced method to improve processing of materials. The
aim of the present study was to develop a finite element model in order to investigate the effect of ultrasonic vibrations
on machinability factors in turning of Inconel 718. Conventional turning in addition to linear and elliptical ultrasonic-
assisted turning were simulated and the effect of these processes on cutting forces, shear angle, chip thickness, sticky
zone, and temperature distributed on tool rake face was analyzed. Besides, the experimental tests were conducted and
the cutting forces have been measured to validate the simulation outputs. As a result, analysis of chip formation shows
that the values higher than 45 for shear angle is achieved when elliptical vibration is added to the cutting process.
Furthermore, increase of shear angle coupled with decrease of temperature on tool rake face causes the sticky zone in
tool–chip contact length to be reduced compared to the conventional turning. Moreover, the influence of cutting speed
on tool–chip engagement time in ultrasonic-assisted turning is simulated.

Keywords
Turning simulation, linear, elliptical, ultrasonic vibrations, shear angle, Inconel 718

Date received: 13 August 2016; accepted: 5 May 2017

cut materials due to its high cutting stability.11–13

Introduction
Ultrasonic vibration-assisted turning (UVAT) is an
advanced technology in which high-frequency vibra-
tions in small amplitude is added on the motion of the
cutting tool. This intermittent vibration is applied on
the cutting tool in the one or two directions which are
denoted by 1D UVAT (one-directional vibration) and
2D UVAT (elliptical vibration), respectively,1 1D
UVAT was Erst proposed in 1958 for conventional
macro-scale turning operation.2 This process demon-
strated a range of improvements in surface roughness
and reduction of power consumption compared to the
conventional turning (CT).3,4 2D UVAT was first
introduced in 1993 by Shamoto and Moriwaki5 and
this process indicated further achievement in the
reduction of cutting force and better machining accur-
acy.6,7 On the other hand, turning of hard materials
such as nickel-based super alloys commonly have
some difficulties due to their rapid strain hardening,
high strength and poor thermal conductivity.8,9 In this
case, conventional turning may not provide all bene-
fits in the desired factors of machinability such as low
cutting force, long tool life and mirror surface Enish.10
Therefore, ultrasonic vibration-assisted turning could
be a promising method for machining of difficult-to-
Accordingly, in recent years various types of theoret-
ical and experimental works have been carried out to
develop the models optimized the cutting operations
for specific materials when ultrasonic vibration is
superimposed to the cutting tool.
Nath et al.14 used one-directional ultrasonic vibra-
tions in turning of hardened steel. The results showed
that tool wear propagation in UVAT was lower than
CT in which better surface finish was also produced
by UVAT. Zou et al.15 represented an experimental
study focused on the influence of 1D UVAT on the
surface roughness by implementation of 3D surface
topography. At the end, they presented the best cut-
ting conditions including ultrasonic amplitude, feed
rate, cutting speed, and depth of cut to enhance sur-
face finish prominently compared to CT. Amini and
Kazemiyoun16 studied the effect of 1D UVAT on the
Faculty of Mechanical Engineering, Department of Manufacturing,
University of Kashan, Kashan, Iran
Corresponding author:
Saeid Amini, Faculty of Mechanical Engineering, Department of
Manufacturing, University of Kashan, Kashan 8731751167, Iran.
Email: amini.s@kashanu.ac.ir
2 Proc IMechE Part E: J Process Mechanical Engineering 0(0)
primary and secondary deformation zones. By using a
quick-stop device and a vision measuring microscope,
they found that ultrasonic vibrations increased shear
angle which finally resulted in the reduction of tool–
chip contact length compared to the CT. In their fur-
ther studies, Bai et al.17 developed an analytical model
to predict orthogonal cutting force produced in 2D
UVAT. The proposed model showed good agreement
with experimental results. To clarify the reason of
improvement in machining accuracy by applying 2D
UVAT, Ma et al.18 developed a theoretical model
based on the thrust force. An empirical model of
thrust and cutting force for 2D UVAT was presented
by Ammouri et al.19 and then it was compared with
the experimental results.
However, several experimental and theoretical
researches have been performed on the use of ultra-
sonic vibrations in metal cutting, and considerable
works remain so that this process can be industria-
lized efficiently. This is due to the general complexity
of metal cutting process that may not be covered in
theoretical and experimental works adequately.
Therefore, applying a finite element method (FEM)
could be helpful to comprehend different aspects of
this process. It can be helpful to clarify the mechanics
of tool–chip engagement in UVAT, and to analyze the
parameters in the primary and secondary deformation
zone. Accordingly, there have been rare studies on the
simulation of ultrasonic vibrations and it is still in the
primary steps.
The FE analysis of UVAT was first reported by
Babitsky et al.20 They developed a simulation model
to predict cutting forces generated during 1D UVAT
and CT. As a result, it was stated that the average
cutting force was smaller in UVAT compared to
CT. In another study, Ahmed et al.21 simulated this
process to analyze the effect of one-directional ultra-
sonic vibration on heat generation in the cutting zone.
It was noted that the use of friction criterion was sig-
nificantly effective on the temperature distribution in
Figure 1. Relative movements of the cutting tool and workpiece: (a) 1D UVAT and (b) 2D UVAT.
the cutting zone. Amini et al.22 tried to represent a
finite element model for prediction of cutting forces
in 1D UVAT process. At the end, it was concluded
that the effect of clearance angle on the magnitude of
the cutting force was insigniEcant, while smaller tool
rake angle produced higher cutting force. Patil et al.23
also developed the same model of 1D UVAT process.
Finally, they reported that there was 40–45% reduc-
tion in cutting force in UVAT compared to the CT.
In this study, FE simulation of conventional turn-
ing, and one-directional and elliptical ultrasonic-
assisted turning processes were conducted to analyze
the effect of ultrasonic vibrations in turning of Inconel
718 super alloy. The simulation results were validated
by running the experimental ultrasonic-assisted turn-
ing in which the cutting forces were measured by using
a dynamometer. Furthermore, the effect of the pro-
cesses on the shear angle, chip thickness, the tempera-
ture and its effects on frictional behavior on the tool
rake face were studied. Moreover, the influence of
cutting parameters on tool–chip engagement time in
UVAT was simulated.
Principle of UVAT
Generally in turning operation, X-axis is the direction
of cutting speed (Vc), Y-axis is the direction of feed
rate (f) and ’ is the shear angle (seen in Figure 1). t1
and t2 are uncut and deformed chip thickness, respect-
ively. While the cutting tool is fixed in CT, it is in a
harmonic motion during the cutting process where
ultrasonic vibration is added to the CT. This har-
monic motion can be divided into linear and elliptical
motion.
1D UVAT
In one-directional ultrasonic vibration, a harmonic
movement is superimposed on the cutting tool in the
direction of cutting speed. With respect to Figure 1(a),
Lotfi and Amini
the cutting tool moves linearly in the defined
  ampli-
tude, in which its position ðUÞ and velocity U_ are as
follows
Ux ¼ a sinð!tÞ ð1Þ
U_ x ¼ a ! cosð!tÞ ð2Þ
where t and a are time and vibration amplitude,
respectively; ! is the angular frequency which is
related to the vibration frequency (! ¼ 2 F ).
2D UVAT
In elliptical ultrasonic vibration, a vertical harmonic
movement is added to the horizontal movement of 1D
UVAT (shown in Figure 1(b)). This motion is parallel
to the feed direction. The cutting tool position is cal-
culated as follows
 respectively (given in Table 1). Also,  is the equiva-
Ux ¼ a sinð!tÞ
ð3Þ
Uy ¼ b cosð!tÞ
And its velocity is
 To model the friction in the tool-workpiece con-
U_ x ¼ a! cosð!tÞ
ð4Þ
U_ y ¼ b! sinð!tÞ
where a and b are vibration amplitude in the direction
of X and Y axis, respectively.
Finite element modeling
As a well-known boundary condition for simulation
of conventional turning, the cutting tool is selected as
a fixed object and the workpiece moves in the direc-
tion of cutting speed with the constant velocity (Vc).
While a harmonic motion is superimposed on the
cutting tool for 1D and 2D UVAT, as explained in
section 2.
In this study, DEFORM 2D software with plane
strain solution was applied to simulate turning oper-
ation. The simulation process was carried out in 5000
steps where each step included 2 e-6 second. Totally,
0.01 s was simulated for each particular cutting
condition.
An updated Lagrangian formulation has been used
to simulate chip formation and to remesh the work-
piece when the elements of the mesh are too distorted.
The workpiece was meshed with the number of 1500
rectangular elements, in which the size ratio of 3 was
used. Moreover, higher mesh density with the size of
5e-6 compared to other areas was applied in the cut-
ting zone due to large gradients of strain, strain rate,
and temperature in this area. The workpiece material
and the cutting tool were Inconel 718 super alloy and
tungsten carbide insert, respectively. While the cutting
tool was defined as a rigid body, the heat transfer
mode was activated to analyze the temperature on
3
Table 1. Material constants for J–C constitutive model.25
Material A (MPa) B (MPa) C N m
IN 718 450 1700 0.017 0.65 1.3
the tool faces. The workpiece was defined as a plastic
object where the Johnson-Cook flow stress model
(equation (5)) was used to represent the constitutive
behavior of workpiece material.
" ! #  m 
n"_ T  Tr
 ¼ ½A þ Bð"Þ  1 þ Cln 1
_"0 Tm  Tr
ð5Þ
where A, B, C, n, and m are the yield strength, the
hardening modulus, the strain rate sensitivity, the
strain-hardening and the thermal softening exponent,
lent flow stress, " is the equivalent strain, "_ is the
plastic strain rate, "_0 is the reference of plastic strain
rate, T is the temperature, Tm is the melting tempera-
ture, and Tr is the reference temperature.24
tact, constant shear model was utilized (equation
(6)). In this equation, k is the shear Fow stress of
the working material at the tool–chip interface and
m is the constant shear friction factor. To define this
constant, an iterative procedure should be carried out
so that the predicted cutting forces are in good agree-
ment with experiments.26 Figure 2 shows this iteration
process.
 ¼ mk ð6Þ
Cockcroft and Latham’s damage criterion27 was
used to predict chip separation from the workpiece.
Based on equation (7), D is the critical damage value
achieved by a uniaxial tensile test. Accordingly, a
crack is initiated by deletion of an element since the
damage value in the element reaches the critical one.28
In this study, the default value (D ¼ 500) given in
DEFORM’s library was used. In this model, "f , ", 
and   are the fracture strain, the effective strain,
and the maximum stress, respectively.
Z "f
D¼   d" ð7Þ
0
Modal Analysis
To find the optimum geometry for fabrication of
vibratory tool, modal analysis was implemented by
using ABAQUS software. Since more than one
mode needs to be excited with the same amplifier
and signal generator, the frequency of vibration
4 Proc IMechE Part E: J Process Mechanical Engineering 0(0)
modes should be as close as possible in designed
tool.11 As it is seen in Figure 3, the designed tool
consists of three sets of piezoelectric (PZT) stacks.
From left to right, half-ring PZT stacks are used for
the first and second sets in which two bending modes
(B-mode) are generated with these sets. Accordingly,
when half-ring PZT stacks in one side expand, the
Figure 2. Flow chart for determination of friction coefficient.
Figure 3. Modal analysis and fabricated vibratory tool.
other ones in another side shrink where each of the
stack series are shifted 180 from each other. As a
result, two B-modes are generated in Z and X direc-
tions by excitement of these two sets of PZT stacks.
The third set includes two complete rings of PZT
which generate longitudinal mode (L-mode) in Y-
direction, as seen in Figure 3. Therefore, three differ-
ent vibratory motions can be generated as follows:
1. Linear vibration can be produced by excitement of
each of three sets of PZT stacks in their related
direction (X, Y, and Z).
2. Elliptical vibration can be produced by simultan-
eous excitement of one set of half-ring PZT stacks
with complete-ring PZT stacks.
3. 3D elliptical vibration can be produced by excite-
ment of all three sets of PZT stacks,
simultaneously.
In this study, the first set of half-ring PZT stacks
has been excited to produce linear vibratory motion in
Z direction (cutting speed direction). Furthermore,
the first and third sets of PZT stacks were simultan-
eously excited for generation of elliptical motion in
Y–Z direction (feed and cutting speed direction).
Due to orthogonal cutting conditions, these two
motions were only used in this work and 3D elliptical
vibration was not used. Note that, there was obvi-
ously no mode between these three modes and the
difference of their resonance frequency was minimized
Lotfi and Amini 5

as much as possible by trial-and-error in the dimen- The workpiece material was Inconel 718 with
sion of vibratory tool geometry in the software. In 50 mm diameter and 0.5 mm thickness. A commercial
Figure 3, fabricated tool is also shown. TCGW-110204 tungsten carbide insert was used in
this study. Furthermore, a Kistler 9257B type dyna-
mometer and the equipment of ultrasonic vibrations
Experimental setup
were exerted to run the experiments. The experimental
In order to verify the simulation model developed set-up and applied instruments are illustrated in
here, a series of orthogonal cutting tests were Figure 4.
conducted on a lathe machine (TN52). The cutting
parameters are listed in Table 2. That being the
case, 18 cutting tests with one replication were totally
Results and discussions
carried out for all three turning methods. In general, a The method of FE analysis utilized in this study is
critical cutting speed is commonly taken into account. shown in Figure 5. Simulation of turning operation
Regarding equation (8), the cutting speed should be has been carried out in the method of conventional,
lower than this value (Vc 5 Vcrit: ). Above this value linear and elliptical ultrasonic-assisted turning. While
leads the operation to be conventional where the tool a constant relative movement existed between tool
rake face never separates from the workpiece and workpiece in CT operation, a harmonic move-
material. ment should be added to the cutting tool in the simu-
lation of turning with ultrasonic vibrations. Figure 5
Vcrit: ¼ 2aF ð8Þ shows one cycle of cutting process when a vibrating
tool was applied. Accordingly, a linear movement
based on equation (1) was superimposed to the cut-
ting tool in 1D UVAT. One cycle of the 1D UVAT
can be divided into six stages. During the first and the
Table 2. Cutting conditions. second stages, the cutting tool starts approaching the
chip, and in the third and fourth stages, it penetrates
Parameters Value
into the workpiece which results in chip formation.
Cutting speed Vc (mm/s) 50, 100,150 The stress becomes the maximum at these stages due
Feed rate f (mm/rev) 0.02, 0.03 to higher plastic work requirement and increase of
Depth of cut ap (mm) 0.5 friction between tool and chip when deformed chip
Tool rake angle00A0 ( ) 0 Fows out on the tool rake face. At the end, the tool
Tool clearance angle  ( ) 7
moves backward and it fully separates from the chip
in the last stage. Besides, this figure represents the
Tool edge radius (mm) 0.03
simulation of 2D UVAT which is divided into eight
Frequency (kHz) 20
stages. In this method, an elliptical movement regard-
Amplitude a (mm) 4 ing equation (3) was applied to the cutting tool. In the
Amplitude b (mm) 4 first stage, the tool starts its circular motion toward
the workpiece and then it contacts the surface that

Figure 4. Applied instruments.

6 Proc IMechE Part E: J Process Mechanical Engineering 0(0)

Figure 5. Simulation of CT, 1D and 2D ultrasonic vibration assisted turning (Vc ¼ 100 mm/s, f ¼ 0.02 mm/rev).

previously machined. At stages 3 and 4, the tool
generates a machined surface, where the actual feed
rate is extremely small. It should be noted that
this small part is not formed into a chip but pushed
into the workpiece under the chip. Next, the cut-
ting tool moves upward roughly in the direction of
shear plane (stages 5 and 6). In this condition, tool–
chip contact length becomes lower which never occurs
in the CT and 1D UVAT due to lack of upward
motion of cutting tool. Finally, the cutting tool with-
draws the chip and moves to the start point at stages 7
and 8.
Lotfi and Amini
Model verification
To validate the results of simulation model developed
in this study, cutting forces were measured in experi-
ments (using a dynamometer) and compared with
those obtained by DEFORM 2D software after
running the simulations. As shown in Figure 2, an
iterative process was used to define shear friction coef-
ficient. Note that, this process was carried out in one
specific cutting condition (Vc ¼ 50 mm/s and
f ¼ 0.02 mm/rev) during CT, 1D and 2D UVAT.
Then all cutting conditions were simulated by using
the selected friction value. During this process, the
value of 0.68 showed best results. Figure 6 indicates
the comparison results where the predicted values of
FE analysis are in good agreement with the experi-
ments. The mean value of cutting forces measured in
experiment and simulation are compared in Figure 6.
The measured cutting forces at different cutting
speeds and feed rates indicate that the average value
of cutting forces is greatly smaller in UVAT compared
to the CT, in which the lowest cutting forces are pro-
duced by elliptical ultrasonic-assisted turning process.
In general, the cutting forces slightly increased with
increase of cutting parameters.
Shear angle and chip thickness
As an ideal approach, many works have been done to
know how the shear angle can be increased in the
primary cutting zone so that it reaches 45 .29 This
f = 0.02 (mm/rev)
(a) 80
60
Fc (N)
40
20
0 shown in Figure 9. Accordingly, the cutting force sta-
CT 1D UVAT
Exp 50 FEA 50 Exp 100 FEA 100
f = 0.03 (mm/rev)
(b) 100
80
60
Fc (N)
40
20
0 specifies that the period of tool–chip engagement in
CT 1D UVAT
Exp 50 FEA 50 Exp 100 FEA 100
Figure 6. Comparison of experimental and simulation
results of cutting force at different feed rates ((a) 0.02, (b) 0.03
(mm/rev)) and cutting speeds (50, 100, and 150 mm/s).
7
increment causes some improvements in cutting pro-
cess such as reduction of deformed chip thickness
which finally results in the decrease of tool–chip con-
tact length and power consumption.30 As it is seen in
Figure 7, the effect of ultrasonic vibration on the
shear angle and deformed chip thickness was studied.
This matter was implemented by comparison of con-
ventional turning with two methods of ultrasonic-
assisted turning in the same step after running the
simulations. The shear-angle graphs extracted from
DEFORM 2D software plus the generated shear
bands are shown in Figure 7(a) and (b), respectively.
Due to excessive fluctuation in the shear-angle values
(particularly in UVAT methods), the mean value of
the graphs is graphically illustrated in Figure 7(c) in
order to have better comparison. Accordingly, the
shear angle increased by using linear vibration and
there was more significant increment by utilizing ellip-
tical vibration. In 2D UVAT, this angle was taken a
step forward in which it is higher than the ideal value.
This event caused deformed chip thickness to be lower
than its primary thickness. In this condition, the chip
compression ratio is more than one which is followed
by increase in the deformed chip length. Regarding
Figure 7(d), generated strain in the chip in 2D
UVAT is approximately two times larger than the
values obtained in 1D UVAT and CT. These condi-
tions can be effective on cutting forces and tempera-
ture distribution, as discussed in the following of this
paper.
Furthermore, the experimental chips obtained
during CT, 1D and 2D UVAT are shown in
Figure 8. The repedability in measurement of shear
angle is very low. However, the increment of
this angle is clearly seen in UVAT methods compared
to CT.
Cutting force
A general profile of cutting force attained in all cut-
ting conditions for CT, linear and elliptical UVAT, is
2D UVAT bilized quickly after running the machining operation
Exp 150 FEA 150 during the conventional turning, while an oscillation
motion is seen for UVAT, due to the harmonic move-
ment of cutting tool. During the tool–chip engage-
ment time, the cutting force increased to its peak
and then decreased to the zero when the cutting tool
disengaged the chip completely. Considering that the
peak of cutting force in linear vibration is nearly equal
to CT, it dramatically decreased when an elliptical
motion was added to the cutting tool. Figure 9(b)
2D UVAT 2D UVAT is more gradual than that happens in 1D
Exp 150 FEA 150 UVAT. This is also seen in Figure 10. Based on this
figure, investigation of cutting forces shows that
increase of cutting speed results in the increase of
tool–chip engagement time in ultrasonic-assisted turn-
ing. This increment continues so that the cutting speed
8 Proc IMechE Part E: J Process Mechanical Engineering 0(0)

Figure 7. (a) Shear-angle graph, (b) strain rate and shear band, (c) chip thickness and the mean value of shear angle, and (d) strain in
the deformed chip during CT, 1D and 2D UVAT processes.

Figure 8. Experimental deformed chips during CT, 1D and 2D UVAT processes.

reaches the critical value, discussed in the
Experimental setup section. More than this value,
the outputs of ultrasonic vibrations show no differ-
ence with conventional turning method.
Heat generation
The simulation results revealed that the temperature
in the primary cutting zone slightly increased when
ultrasonic vibrations have been superimposed to the
Lotfi and Amini 9

shown in Figure 11. Lower temperature on the tool

CT 1D UVAT 2D UVAT
(a) 120 rake face causes decrease of the sticky friction in the
secondary deformation zone which results in improv-
100
ing the desired factors of machinability.16
80 Experimental observation of sticky length in
Fc (N)

60 Figure 11 shows that it is reduced when ultrasonic

vibration is added to the cutting tool.
40
This decrement in the temperature and then in
20 sticky friction can be explained by reduction of con-
0 tact time and passing the air when the vibrated cut-
0 0.001 0.002 0.003 ting tool disengages the chip. Therefore, increase of
t (s)
amplitude (a) and frequency (F) decreases engage-
(b) 120 ment time resulting lower friction and temperature
on tool rake face. Furthermore, it can be proved
100
theoretically, in which Chou32 represented a dimen-
80 sionless variable () based on the ratio of tool elas-
tic energy to the surface energy within per unit
Fc (N)

60
Tool-chip volume at tool–chip interface. This variable was
40
engagement time named the cutting seizure number and its relation
20 with ultrasonic vibrations has also been identified. It
0
was shown that larger tool elastic energy reduces
0.00101 0.00102 0.00103 0.00104 0.00105 0.00106 tool–chip sticky length. Then, the following relation
t (s) was expressed

Figure 9. Cutting force profile in CT, 1D and 2D UVAT:  / ðFaÞ2 ð9Þ

(a) complete process, (b) a period of process (Vc ¼ 100 mm/s,
f ¼ 0.03 mm/rev).
With consideration of maximum linear vibration of
cutting tool (Vcritical ¼ 2aF), equation (9) can be
rewritten as follows
CT 50 CT 100 CT 150
1D UVAT 50 1D UVAT 100 1D UVAT 150  
Vcritical 2
120
2D UVAT 50 2D UVAT 100 2D UVAT 150 / ð10Þ
2
100

80 With respect to the equation (10), higher ampli-

Fc (N)

60 tude (a) and higher frequency (F) in UVAT increase

40
20
0 sequently the sticky length, which cannot be hap-
0.001012 0.001017 0.001022
t (S)
Figure 10. The effect of cutting speed on tool–chip engage-
ment time.
cutting tool. It can be explained by additional energy
coming into the cutting system with ultrasonic vibra-
tions.31 On the other hand, FE analysis of the heat
generation showed that lower temperature generated
on the tool rake face in the ultrasonic assisted turning
which is much more important area due to frictional
properties between tool and chip (Figure 11). Among
these three methods, 2D UVAT had the lowest tem-
perature which is due to generation of lower deformed
chip thickness. It should be noted the temperature was
analyzed after 4000 steps of simulation (0.01 s) as
maximum linear vibration which is proportional to
. This increment reduces the temperature and con-
0.001027 0.001032 pened in CT when maximum linear vibration of
cutting tool is equal to zero. Moreover, increase
of shear angle by applying the ultrasonic vibrations
can also be effective on this region. Based on equa-
tion (11) represented by Özel and Zeren,33 the sticky
region decreases with increase of shear angle and
decrease of deformed chip thickness.lst is the
length of sticky region and t2 is the maximum
thickness of the secondary zone.
t2
lst ¼ ð11Þ
sinð’  Þ
However, tool wear investigation was not carried
out in this paper, and temperature results can give
information about possible tool wear.34 By these
observations, the acceleration of tool wear rate can
be suppressed by using ultrasonic vibrations.
10
Figure 11. Temperature distribution on tool rake face and experimental sticky length on chip surface.
Conclusions
2D simulation of conventional, linear and elliptical-
assisted turning has been carried out in order to
analyze the cutting process of Inconel 718 super
alloy. Ultrasonic equipment and dynamometer were
used in experimental tests to verify the model devel-
oped in this work. The effect of ultrasonic vibrations
on cutting force, shear angle, chip thickness in pri-
mary cutting zone, and temperature in the secondary
cutting zone were studied. The main conclusions of
this work are given as follow:
. Comparison of cutting forces show that predicted
and experimental values are adequately in good
agreement.
. Increase of cutting speed results in the increase of
tool–chip engagement time when ultrasonic vibra-
tion is used.
. While the peak of cutting force in linear vibration
is nearly equal to conventional turning, it is lower
in elliptical vibration in which the average value of
this factor was significantly lower in turning with
linear and elliptical ultrasonic vibrations compared
to the conventional turning.
. Shear angle increases when ultrasonic vibration is
added to the cutting tool.
. The value more than 45 for shear angle can be
achieved by using elliptical vibrations.
. Deformed chip thickness by the value of lower
than the uncut chip thickness can be produced
by implementation of elliptical ultrasonic
vibrations.
Proc IMechE Part E: J Process Mechanical Engineering 0(0)
. The harmonic movements of cutting tool causes
decrease of temperature in the tool–chip contact
zone which finally results in the reduction of fric-
tion in the secondary deformation zone.
Acknowledgement
The authors wish to thank the Production Lab of University
of Kashan for their technical support.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of
this article.
Funding
The author(s) received no financial support for the research,
authorship, and/or publication of this article.
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