فهرست نشریات علمی دسترسی آزاد ایران

Conventional turn-milling (CTM) integrates turning and milling operations in a single setup, enhancing precision, efficiency, and dimensional accuracy while reducing setup time. Ultrasonic-assisted turn-milling (UATM) builds upon CTM by incorporating high-frequency, small-amplitude vibrations, which further reduce cutting forces, boost machining efficiency, and improve dimensional accuracy. This study compares the performance of CTM and UATM on alloy steel 1.7225, using Minitab software and a multifactorial design to analyze the effects of tool and workpiece rotational speeds, feed rate, and depth of cut on cutting forces and surface roughness. The results showed that UATM reduced cutting forces by 13.79% and surface roughness by 21.39% compared to CTM, due to the transformative impact of ultrasonic vibration on the cutting process, which led to intermittent cutting and reduced forces. ANOVA was employed to assess parameter impact, and a mathematical model with 91.41% desirability was developed to study the correlation between machining parameters and response variables. Single-objective optimization indicated that in the UATM process, the depth of cut, tool rotational speed, and workpiece rotational speed decreased cutting force by 14.74%, 13.76%, and 13.42%, respectively. Additionally, in the UATM process, the tool and workpiece rotational speeds were identified as the most influential parameters on surface roughness.