The International Journal of Advanced Manufacturing Technology (2018) 97:2173–2192

https://doi.org/10.1007/s00170-018-2087-6

ORIGINAL ARTICLE

Hybrid machining process: experimental and numerical analysis

of hot ultrasonically assisted turning
Riaz Muhammad 1 & Naseer Ahmed 1 & Himayat Ullah 2 & Anish Roy 3 & Vadim V. Silberschmidt 3

Received: 26 October 2017 / Accepted: 25 April 2018 / Published online: 8 May 2018
# Springer-Verlag London Ltd., part of Springer Nature 2018

Abstract
A hybrid turning is presented for turning of Ti-15V-3 Al-3 Cr-3 Sn alloy. In this technique, cutting insert is vibrated in velocity
direction with the help of ultrasonic transducer and external heat is provided to the machined workpiece to gain collective benefits
of both arrangements in cutting of hard-to-cut alloys. The studied alloy was investigated numerically and experimentally using
hybrid turning process to determine its rewards in decline of measured cutting forces and enhancement in quality of machined
surface. The assessment for thermal evolution in the cutting process was carried out both numerically and experimentally, and an
accurate prediction of process zone temperatures is achieved. A significant improvement in dry turning of the studied alloy was
achieved in terms of substantial decline in cutting forces and no substantial alterations in the metallurgy of the tested material. An
elastoplastic thermo-mechanically coupled finite-element model for oblique-turning process is established to investigate the
effect of heat and vibration on output parameters numerically. The developed model was used to explore the influence of selected
machining parameters (depth-of-cut, feed rate, cutting speed, and tool nose radius) on three components of forces, stresses, and
process zone temperature. Comparative case studies were executed with the developed models of conventional-turning, hot-
conventional-turning, and hybrid turning and were confirmed by the outputs from tests carried out on the in house prototype
available at Loughborough University, United Kingdom. The model was used for two-dimensional ultrasonic vibration in all
three axis and resulted no significant drop in the cutting forces when compared to the studied hybrid turning process.

Keywords Finite element . Hybrid machining . Turning . Machining . Titanium

1 Introduction force in aerospace and biomedical industries. In this field,

titanium alloys offer clear advantages when compared to steel
Component weight reduction, increased resistance to corro- components. They have comparable strength with modern
sion and thermo-mechanical fatigue, has become the driving steels at approximately half the density and excellent fatigue
performances and resistance to aggressive environments [1].
At the same time, they are not affected by the shortcomings
• A hybrid machining technique is introduced for the machining of beta
titanium alloy. which are commonly observed in composite materials: low
• This technique resulted significant reduction in cutting forces and resistance to impact and excessively complicated mechanical
improvement in surface roughness. behavior. Ti-based materials offer great cost reductions by
• Experimental results were validated with the developed finite element extending life of components and reducing the operative costs
model.
which, in aerospace industry, are also closely linked to weight.
Titanium and its alloys are, however, known for their ma-
* Riaz Muhammad
[email protected]; [email protected] chining difficulties [2]. Their excessive chemical reactivity
and truncated thermal conductivity at elevated temperatures
1 result in need to use specialized cutting tools which are ob-
Department of Mechanical Engineering, CECOS University of IT
and Emerging Sciences, Peshawar, KPK, Pakistan served anyway to have a shortened life in conventional ma-
2 chining operations [3]. This leads to the need to machine with
CESAT, H 11/4, Islamabad, Pakistan
reduced cutting speed and feeds, with an increase of the ma-
3
Wolfson School of Mechanical, Electrical and Manufacturing chining time and consequently of per-component costs. In
Engineering, Loughborough University, Loughborough,
Leicestershire LE11 3TU, UK addition, Ti-alloy Young’s modulus is generally low when
2174 Int J Adv Manuf Technol (2018) 97:2173–2192

Table 1 Properties of Ti-15333 [20, 25] Table 2 Feed-speed-depth of cuts used in experimental tests and
simulations [25]
Workpiece material Ti-15 V-3 Al-3 Cr-3
Tested parameters Magnitude
Diameter, D (m) 0.065
Length, L (m) 0.5 Machining speed; V (m/min) 10, 20, 30, 40, 50, 60, and 70
Modulus of elasticity, E (GPa) 87 Depth-of-cut; ap (mm) 0.1, 0.2, 0.3, 0.4, and 0.5
Yielding-strength, σy [Pa] 558.85e6 Feed rate; fr (mm/rev) 0.1
kg
Density, ρ (m3 /) 4900 Initial workpiece temperature; T (°C) 20, 100, 200, and 300
W
Thermal cond., k (Km ) 8.10 Freq. in HT; f (Hz) 20,000
Thermal expansion co-efficient α [K1 ] 8.4e6 Amp. in HT; a (mm) 0.08
Specific-heat, Cp [ gJ -oC] 0.6
Ultimate strength, σul (Pa) 1200e6
Several attempts were made for the titanium and its al-
loy machinability enhancement, either by improving the
compared to that of steels. This leads to spring-back and chat- characteristics of the alloy or by improving the cutting
ter during the machining operations resulting in poor surface process. Improving the machining properties of the alloy
integrity with the need of expensive post-processing of the without degradation of its desirable mechanical properties
finished components [4]. At low cutting speeds, these alloys is challenging as minute changes in the chemical compo-
produce long continuous chips, entangling on the cutting tool, sition have large effects [6–8]. Several efforts have been
thus rendering automated machining impossible [5]. exercised to shrink the propensity of the alloy for

Fig. 1 a Block diagram and b HT

setup [25]
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Fig. 2 Recorded forces at 300 °C

(V = 10 m/min; ap = 0.3 mm) [25]

continuous chips by doping of different alloying elements While known from more than four decades, ultrason-
which should decrease adhesion between chip segments, ically assisted machining has only recently developed
resulting in discontinuous chips. Improving the cutting enough to be introduced commercially by DMG-Mori
process offers the guarantee that fatigue and mechanical Seiki. Additionally, in recent decades, improvements in
properties of the alloy are generally preserved. Cooling the efficiency and operative life of ceramic transducers
and lubrication improvements by high-pressure coolant allowed a developed machining system called
flow generally offer limited advantages due to the high Ultrasonically-Assisted-Turning (UAT) [15]. In this dry
contact pressure between chip and tool and low thermal technique, a hard tool is subject to high-frequency vibra-
conductivity of the alloy [9]. Additionally, high costs in- tion preferentially in the cutting direction and resulted in
volved with environmentally friendly disposal of spent several documented improvements in machining of head-
fluids reduce the attractive of those techniques to the extent strong alloys [16–23].
that some researcher claimed costs associated with cutting The most striking effect reported was the pronounced
tools are comparable to those of cutting fluids [10, 11]. decline in the levels of observed forces with forced
Similarly, improvements of the cutting process by means vibrated tool [24, 25]. The consequent reduction of
of hybrid machining techniques [12] or vibration-assisted chatter and spring-back observed improved dimensional
machining were proven to offer significant advantages accuracy of the finished components. Similarly, a signif-
when compared to conventional dry machining processes icant enhancement in surface finish was also measured
[13, 14]. [20].

Fig. 3 Process zone temperature

history at 0.3 mm depth of cut,
10 m/min cutting speed; a HCT
and b HT
2176 Int J Adv Manuf Technol (2018) 97:2173–2192

180
2 Experimental details
160 Fx Fy

140 2.1 Workpiece and cutting tool

120
An aged and solution treated, Ti-15333 alloy bar ingot having
Force, N

100
80
a 0.5 m length and diameter of 0.065 m was used in the tests.
An ephemeral description of the properties of the studied alloy
60
is listed in Table 1.
40
The binary coated DNMG 150608 MF1 CP500 inserts
20 provided by SECO were used in tests as proposed for cutting
0 depths, ranges from 0.2 to 0.3 mm with 0.05 to 0.25 mm/rev
100 200 300 400 500 feed rate and 45 m/min speed in machining of high-strength
Depth of cut, µm
alloys.
Fig. 4 Level of cutting forces in CT at a cutting speed of 10 m/min and
various depth of cuts
2.2 Cutting force measurement
In the current work, Ti-15 V-3 Al-3 Cr-3 Sn (named as Ti-
15333) was machined with a novel machining technique Experimental studies were conducted on universal Harrision
called hybrid turning (HT) process, to investigate its effects M-300 Lathe machine for CT, HCT, and HT. To capture the
on the machining operations and demonstrated the observed resulting forces, a Kistler piezo-electric dynamometer (KIAG-
enhanced surface quality with further decline in insert forces SWISS/Type9257A) was used. The dynamometer has the ca-
as related to Conventional-Turning (CT) and Hot- pability to measure two components of forces Fx (tangential
Conventional-Turning (HCT). Furthermore, a 3D parametric component) and Fy (radial component) with a sensitivity of ±
finite element (FE) model was generated for investigating the 0.1 N as shown in Fig. 1. To monitor the vibrational parame-
load and response of the material on the cutting insert at dif- ters in experimentations, a LASER vibrometer manufactured
ferent tested conditions. The model has the capability to be by Poltec-GmbH was used.
used for the prediction of forces, temperature, and stresses in The workpiece was encapsulated by a band resistance
unidirectional and 2D vibration-assisted turning. heater to apply external heat to it (300 °C ± 10 °C). A

Table 3 Experimental cutting forces in HCT and HT

Depth of cuts (μm) Workpiece temperature HCT (N) HT (N) Reduction (%) Reduction (%) Reduction (%)
(°C) CT vs HCT HCT vs HT CT vs HT
ap T Fx Fy Fx Fy Fx Fy Fx Fy Fx Fy
100 100 39 ± 1 24 ± 3 7±1 4±1 16.5 5.8 82.0 83.3 84.8 83.6
200 100 63 ± 6 35 ± 3 13 ± 2 7±1 9.3 12.9 79.3 80.0 80.9 82.4
300 100 90 ± 8 42 ± 5 20 ± 2 9±2 8.4 8.7 77.7 78.5 79.3 80.0
400 100 121 ± 10 47 ± 5 28 ± 2 13 ± 2 3.0 11.6 76.8 72.3 77.8 76.2
500 100 144 ± 10 52 ± 6 36 ± 3 16 ± 2 4.3 14.5 75.0 69.2 75.9 73.6
100 200 34 ± 4 23 ± 2 7±2 4±1 27.7 9.2 79.4 82.6 85.8 85.0
200 200 58 ± 6 28 ± 3 10 ± 2 6±2 15.7 29.7 82.7 78.5 85.2 84.0
300 200 87 ± 7 38 ± 4 19 ± 2 8±2 11.4 17.2 78.1 76.3 80.4 82.6
400 200 118 ± 8 41 ± 6 24 ± 3 11 ± 2 5.6 23.7 79.7 73.1 80.9 79.2
500 200 141 ± 10 49 ± 6 30 ± 3 12 ± 2 6.3 18.6 78.7 75.5 80.1 79.6
100 300 34 ± 4 18 ± 3 3±1 2±1 28.1 30.4 91.1 88.8 94.3 91.7
200 300 59 ± 5 26 ± 3 10 ± 2 5±2 15.1 35.3 83.0 80.7 85.4 87.2
300 300 77 ± 5 35 ± 4 16 ± 2 7±2 20.9 23.4 79.2 77.1 83.2 84.7
400 300 105 ± 7 38 ± 5 21 ± 3 10 ± 2 15.3 28.2 80.0 73.6 83.0 81.1
500 300 140 ± 6 44 ± 6 27 ± 3 11 ± 3 7.1 26.2 80.7 75.0 81.7 80.4
Cutting forces for CT
Depth of cuts (μm) 100 200 300 400 500
Fx 47 ± 7 69 ± 4 98 ± 8 124 ± 8 150 ± 11
Fy 25 ± 4 40 ± 7 46 ± 5 54 ± 4 60 ± 11
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Fig. 5 Thermal analysis of the process zone in CT and HCT (V = 10 m/min; ap = 0.3 mm)

standardized K-type thermo-couple coated by Teflon and a temperature and was also validated using the FLIR
FLIR ThermaCAMTM SC-3000 infra-red system was used ThermaCAM™ SC-3000 system.
to calculate workpiece temperature during HT. The feed- Table 2 presents the cutting conditions used in experimen-
back system imbedded in the controller of the heater en- tations. The listed levels of temperature were chosen based on
sured accurate prediction of the workpiece surface the metallographic reaction of Ti-15333 to the applied

Fig. 6 Thermal analysis of the process zone in CT and HT (V = 10 m/min; ap = 0.3 mm)
2178 Int J Adv Manuf Technol (2018) 97:2173–2192

Fig. 7 Temperature levels and

calculated plastic-heat generation

temperature [26]. The test was conducted for each set of cut- movement of the heater was controlled manually in all tests
ting parameters and was lasted for about 75 s to measure the for HCT and HT processes as suggested by the manufacturer
required output parameters. The machining conditions were to avoid thermal damage to the camera. The recorded quanti-
established to the chosen magnitude in the first 20 s, HCT for ties were studied using the Quick-view Software to analyze
20 s, and followed by HT for approx. 30 s as shown in Fig. 2. data as shown in Fig. 3.
Individual test was conducted 5 to 6 times to acquire realistic
data.
During HT, random vibrations in the axial and radial direc- 2.4 Surface, sub-surface tests
tion having an amplitude of approx. 0.0001 and 0.0003 mm,
respectively, were observed, whereas in the velocity direction, The surface roughness of machined specimens was carried out
a magnitude of 0.008 mm was recorded. using Zygo® newview-5000 interferometry equipment. The
standard, arithmetic means surface roughness parameter (Ra)
2.3 Process zone temperature in CT, HCT, and HT was measured using the machine perpendicular to the feed
marks. Measurements of Ra were taken at various locations
In CT, HCT, and HT, the FLIR ThermaCAM SC-3000 system of the specimens and all tests were repeated five times to get a
was operated for thermal analysis of the process zone. The reasonable statistical data for Ra.

Fig. 8 2D field plots of surface texture at V: 10 m/min and ap: 0.3 mm

Int J Adv Manuf Technol (2018) 97:2173–2192 2179

Fig. 9 Surface roughness in HCT

and HT at various temperatures

Similarly, titanium alloys are very responsive to metallur- under study in CT, HCT, and HT. Material response and chip
gical changes and oxidation, when exposed for longer period shapes were also investigated by analyzing chips produced in
of time to high temperature (for more than 1 h, approximately different turning process.
at 450 °C) [26]. In the current study, all investigations were
conducted in open air without any shielding. Supplementary,
in CT and HT processes, several hundred degrees-centigrade
raised in temperature was noted at the insert-workpiece inter- 3 Discussion on experimental results
action. Therefore, light microscopy followed by scanning
electron microscopy (SEM) and microhardness testing of ma- 3.1 Measured cutting forces
chined specimens were carried out using Nikon Optiphot, Carl
Zeiss Leo 1530 VP electronic microscope and NanoTest The measured cutting forces for various depths of cuts (ap) in
NTX3, respectively, to observe the behavior of the material all experiments performed for CT, HCT, and HT are shown in

Fig. 10 LM of machined samples

2180 Int J Adv Manuf Technol (2018) 97:2173–2192

Fig. 11 SEM examination of samples

Fig. 4. A substantial decline in Fx and Fy was seen in presence tool. As Fx on the tool was 46 N at 0.1 mm depth of cut,
of vibration and external heat in HT. whereas at a p = 0.5 mm, 27 N in HT was measured.
A gradual increase in the level of Fx from 47 to 150 N was Therefore, MRR increased substantially in HT. The measured
observed with a growth in ap from 0.1 to 0.5 mm, respectively. results demonstrated that application of both heat and vibra-
Similarly, a rise in Fy from 25 to 60 N was observed at the tions in machining of Ti-15333 enhanced its machinability
same depth of cuts. and resulting, a significant fall in the level of Fx and Fy as well
Application of external heat to Ti-15333 and vibrations on as increased considerably its MRR.
the cutting insert yielded substantial reduction in Fx. A notice-
able drop of 8 and 79.7% in Fx was achieved at 100 °C and 3.2 Thermal analysis
ap = 0.3 mm in HCT and HT, respectively (Table 3). Similarly,
further decline of 3 and 5% was measured at 200 °C in both The scattering of the process zone temperature in studied pro-
HCT and HT, respectively. The drop in HT and HCT reached cesses is presented in Fig. 5. An upper level of process zone
to 83.2 and 20%, respectively, as compared to CT. temperature was noted in HT as compared to CT due to exter-
Similarly, a visible reduction in the level of Fy was recorded nal heat supplied to the Ti-15333 and vibration applied on the
in HT process (see Table 3). A reduction of 80 and 8% in Fy cutting insert. The process zone temperature in HCT (at
was witnessed in HT and HCT, respectively, for 100 °C 300 °C) was nearly 250 °C higher than CT. The increase in
preheated condition. An additional increase of 100 °C in temperature is steady with the extent of heat supplied to Ti-
workpiece temperature resulted in a decline of 9.5 and 11% 15333.
in HCT and HT, respectively. Also, the fall in Fy at 300 °C is Also, the chip temperature increased, significantly, with
reached to 23 and 84% in HCT and HT, respectively. ultrasonic vibrations and external heat in HT as presented in
The assessment of HT with CT resulted in a noteworthy Fig. 6. The potential reason is the added influence, associated
decline in measured cutting forces. At a depth of cut of to indulgence of vibration-energy and external heat [22]. An
0.1 mm, the reduction in Fx and Fy is approx. 95% in HT. approximately 300 °C higher temperature was recorded in HT
The drop in Fx and Fy declines with growth in the level of when linked to that measured in CT at 300 °C preheated con-
ap, and eventually, a steady reduction of 81–85% is achieved dition. Similarly, at 100 and 200 °C preheated conditions, the
in HT above 0.2 mm depth of cuts and at 300 °C preheated process zone temperatures are 192 and 224 °C higher than CT
condition. The decline in Fx and Fy was primarily credited to in HT, respectively.
the drop in strength of Ti-15333 at higher temperatures [27]. The calculated decline in plastic-heat generation in HCT
Hence, the material removal rate (MRR) in HT is on the upper and HT is presented in Fig. 7. A gradual decline in plastic-heat
hand with comparison to CT for the same level of Fx and Fy on generation was noted, decreasing the extent of energy

Fig. 12 Backscatter examination of samples

Int J Adv Manuf Technol (2018) 97:2173–2192 2181

necessary to eliminate the required quantity of material in

HCT and HT.
During experimentation, the engagement zone of the
workpiece-tool is not discernable to the IR system.
Therefore, all measured temperature levels represent the chip
temperatures in all studied processes. However, a good pre-
diction of produced process zone temperature was accom-
plished for CT, HCT, and HT.

3.3 Surface and sub-surface analysis

In HT, excess of 50% improvement in surface topography

parameters was found when results are compared to that of Fig. 14 Split-Hopkinson test results at room temperature and different
CT. In a 2D field plots, texture of machined surfaces in CT, strain rates [31]
HCT, and HT is shown in Fig. 8. Notably, periodicity is seen
for CT machined surface, but for HT, it is somewhat short- needle shape precipitate was witnessed in Ti-15333 chips,
ened. The attained surface feature in both HCT and HT was exposed to above 450 °C temperature for more than 1 h
statistically identical. [26]. In the current study, a concentrated temperature of
The Ra value of 1.73 μm was observed in CT of Ti- 586 °C was measured in HT, and to nullify the formation of
15333 at 10 m/min cutting speed and ap = 0.3 mm. A signif- alpha precipitate (α-Ti) during the cutting operation, the col-
icant drop in Ra was measured in HT and HCT, when com- lected samples were analyzed using scanning electron micros-
pared to the results achieved in CT as shown in Fig. 9. A 62 copy (SEM). In the analysis, a vastly deformed zone of nearly
and 59% drop in the Ra level was noted in HT and HCT, 3–5 μm was seen near the cut surface as shown in Fig. 11. The
respectively. Application of external heat made Ti-15333 region was etched differently; however, no confirmation of the
softer, enabling easier chip-flow to the insert cutting edge, α-Ti was noted in SEM, and therefore, the backscatter analy-
yielding enhancement in the surface finish of the processed sis was carried out to further investigate the observed de-
alloy. Similarly, the vibration imposed on the cutting insert formed layer. In the backscatter investigation, the existence
further polishes the machined surface. of α-Ti was excluded, as shown in Fig. 12. Though it is
Additionally, the effect of heat and vibration on Ti-15333 established that the differently imprinted zone in HT, HCT,
in HCT and HT was investigated through light microscopy and CT is the deformed material witnessed in chip formation
(LM). The results showed no marks of oxidation and metal- examination of Ti-15333 [26], hence, HT established an
lurgical variations with temperature and heat as shown in extensive drop in Fx and Fy as well as noticeable enhancement
Fig. 10. The observed grain size in studied alloy is not uniform in surface quality [28] with no sub-surface changes in the
and was varying all over the specimen as reported [26]. A studied alloy.

Fig. 13 FE model with insert

geometry
2182 Int J Adv Manuf Technol (2018) 97:2173–2192

Fig. 15 Ti-15333 flow stresses at strain rate of 3300/s and various

temperature [31] Fig. 17 FE results of forces in CT (V = 10 m/min; fr = 0.1 mm/rev; ap =
0.3 mm)

4 FE modeling of CT and HT processes used to discretize the insert in to 8000 elements. Vibration
of frequency ( f ) and amplitude (a) was applied on the
A commercial code MSC Marc Mentat was used to establish insert in the X-direction in HT as shown in Fig. 13. In
implicit FE model for HT and CT [29]. The models were addition, to the study of one-dimensional vibration modes,
based on Lagrangian procedure which offers a transient anal- elliptical vibrations were also imposed on the insert to
ysis and incorporating the frictional interaction between the study its effect on cutting forces. The following equations
workpiece and insert. of motion were used to define vibration superimposed on
the cutting tool:
4.1 Model description and features
xðt Þ ¼ acosð2πft Þ; ð1Þ
In machining operations, the process zone temperature in-
creases significantly and considerably effect thermal and me-
chanical properties of materials owing to non-linear material
response at high temperatures. The established model incor-
yðt Þ ¼ bcosð2πft þ φÞ; ð2Þ
porates non-linear material responses with temperature
growth.
The true edge geometry of the DNMG-080615 tool in- Here, a is the amplitudes in tangential direction while b in
sert is modeled as rigid body in the current models to certify radial direction; f is the frequency, φ phase angle, and t is the
all three components of forces in HT and CT having heat time.
transfer capabilities. Four-noded tetrahedron elements were

Fig. 18 Simulated forces in HT in one complete vibration cycle (V =

Fig. 16 Modified material response used in FE simulation at 600 °C [31] 10 m/min; fr = 0.1 mm/rev; ap = 0.3 mm; T = 300 °C)
Int J Adv Manuf Technol (2018) 97:2173–2192 2183

Fig. 19 Experimental and

numerical result comparison

For elliptical vibrations, amplitude of 8 and 4 μm was A workpiece having a height of 0.5 mm + ap, width of
applied on the insert in tangential and in radial direction, 1.3 mm, and length of 5 mm is modeled in the FE model.
respectively. The cutting velocity was assigned to the workpiece (see
Fig. 13). Firstly, eight-noded hexahedral elements with
0.05 mm of length were used to mesh the workpiece. To attain
local mesh refinement, the global remeshing was defined to
regions close to the cutting edge resulting elements having
length equal to 0.0125 mm after mesh convergence tests.
The assigned mesh was finalized after mesh convergence
study.

4.2 Material model

A linear piecewise material model is implemented to include

the flow stress behavior of studied alloy at high strain rates and
temperatures. For Ti-15333 [30], Split-Hopkinson (SH) tests
were conducted at Tampere University of Technology (TUT),

Fig. 20 The levels of Fx, Fy, and Fz a HCT and b HUAT (ap = 0.3 mm, Fig. 21 Reduction in forces (as compared to CT) at studied temperature
V = 10 m/min, and fr = 0.1 mm/rev) levels in HT
2184 Int J Adv Manuf Technol (2018) 97:2173–2192

Fig. 22 Accumulation of materials in HT at 500 °C in feed direction

Fig. 24 Temperature spreading on rake face (V = 10 m/min; ap = 0.3 mm;
Finland. In the acquired results at different strain rates, tem- fr = 0.1 mm/rev; T = 300 °C)
peratures are presented in Figs. 14 and 15.
The main limitation of the SH setup at TUT is its function- strain magnitudes are restricted by the ultimate tensile
ality at strain rate of 3300 s−1 where as in machining process- stress (UTS). The temperature and strain rate sensitive
es, it extended to 105 s−1 [31, 32]. Therefore, an interpolation material model used in our FE simulations included of
method using FE simulations of SH tests was adopted to in- various stress-strain curves achieved from four different
corporate material response at 105 s−1. Additional detail about temperature levels (20, 600, 800, and 950 °C) and four
the study can be found elsewhere [19] (Fig. 16). strain rates (0.1, 1, 3331, and 105 s−1). All the data
Moreover, the curves used in material model were used in material model was fed to the software in tab-
changed in a manner that the levels of stress for higher ulated form.

Fig. 23 Temperature spreading in

CT, HT, and HCT (V = 10 m/min;
ap = 0.3 mm; fr = 0.1 mm/rev; T =
300 °C)
Int J Adv Manuf Technol (2018) 97:2173–2192 2185

Fig. 25 Temperature plot on rake

face

5 FE outcomes and discussion Fx, Fy, and Fz was 20, 22, and 40%, respectively, in HCT when
compared to the results achieved in CT at room temperature. A
5.1 Cutting force good agreement between simulated and experimental results
was attained with an average error up to 10% (Fig. 19).
The developed oblique model was used to calculate Fx, Fy, In the earlier work of Muhammad et al. [19, 25], they
and Fz (axial component of force) in CT, HCT, and HT. The demonstrated that application of vibration on the cutting insert
magnitude of Fx was 110 N in CT as shown in Fig. 17. The resulted a decline of 75, 67, and 52% in Fx, Fy, and Fz, respec-
levels of Fy and Fz were 48 and 20 N, respectively, which were tively. However, in the current work, it was concluded that
achieved through FE simulation. At the initial stage, the addition of heat with vibration resulted an additional drop of
achieved levels of Fx, Fy, and Fz on the insert were zero before 15, 11, and 16% in Fx, Fy, and Fz, respectively.
contact. The extents of these forces swiftly increased with the The model was used for various heat sources covering from
tool-workpiece contact, and after a full engagement of the tool 100 to 500 °C to analyze the cutting forces. A measured drop
with the workpiece material, a steady-state magnitude of cut- in Fx, Fy, and Fz was noted with an increase in temperature in
ting forces was seen in CT. The small fluctuation in achieved both HT and HCT (Fig. 20). A drop of 28 and 82% in Fx was
forces is resulted by global-remeshing used for chip separation observed at 500 °C in HCT and HT, respectively. Also, a
in the current simulation. decline of 28 and 78% in the Fy and 44 and 63% in the Fz
With a combined effect of vibration and external heat, a was recorded in HCT and HT, respectively (Fig. 21).
sizeable decline in forces is witnessed in HT. In the penetra- From simulation results, some minor reduction in Fx was
tion stage of the insert in HT, the insert indented the workpiece achieved at 500 °C, whereas the level of Fy was the same and a
and resulted a peak level of Fx, Fy, and Fz at full penetration. slightly growth in Fz was noted. The main cause is unneces-
The simulated peak force levels were lower in scale when sary thermal softening of simulated specimen as presented in
matched with CT, but nearly identical to HCT. The cutting Fig. 22. Hence, a recommended temperature for the studied
forces start to drop and eventually reached to zero at full re- alloy in HT is 300 °C.
traction (Fig. 18).
A substantial decrease in Fx of approximately 80.5% was 5.2 Thermal analysis
achieved in HT. The average levels of Fz and Fy decline from
20 to 6 N and from 48 to 11 N, respectively. Hence, applica- The recorded process zone temperature in CT was relatively
tion of vibration on insert and heat to the workpiece in HT lower as compared to HT and HCT. The heat externally ap-
decreases the forces considerably. On the contrary, the drop in plied to Ti-15333 significantly increased the process zone

Fig. 26 Plastic-strain plots in a

CT and b HT
2186 Int J Adv Manuf Technol (2018) 97:2173–2192

temperature in HCT and HT. However, the level of tempera-

ture recorded from FE simulation in HT was higher than that
in HCT at studied cutting conditions as presented in Fig. 23
and can be credited to the surplus energy (vibration) imposed
on the insert. The developed FE models have an added advan-
tage of revealing temperature profile in sections not observ-
able to IR system in experimentations. In HT simulations, the
calculated process zone temperature of 680 °C was recorded
as compared to 600 °C in experimentation for the same cutting
conditions.
The spreading of heat on the face of insert was plotted from
FE simulation of CT, HT, and HCT. The highest temperature
was identified at the rake face center (Fig. 24). The tempera-
ture spreading on the rake face of the insert changes with the Fig. 28 Temperature spreading at ap = 400 μm at t = 3 ms

Fig. 27 The level of Fx, Fy, and Fz

at studied depths of cuts (V =
10 m/min; fr = 0.1 mm/rev; and
T = 300 °C)
Int J Adv Manuf Technol (2018) 97:2173–2192 2187

insert position in HT. A temperature of approx. 303 and

295 °C was noted at full penetration and retraction position
(see Fig. 25). On the contrary, 100 and 290 °C in CT and HCT,
respectively, were measured. Similarly, plastic-strain was re-
duced by 33% in HT when compared to the level of plastic
deformation observed in CT as presented in Fig. 26.

5.3 Effect of depth of cut

The FE simulation outcomes shown in Fig. 27 demonstrate Fig. 30 Process zone temperature in HT (70 m/min) at t = 1 ms
the change in forces for tested depth of cuts. It is identified that
Fx is a principal component compared to Fz and Fy in both
experimentations and simulations. A linear growth in the level simulated results as presented in Fig. 27. A drop of approxi-
of Fx, Fy, and Fz was noted with rise in the depth of cut. A mately 80.5, 76.2, and 68.3% in Fx, Fy, and Fz was detected in
worthy agreement was accomplished in experimental and HT at tested conditions.

Fig. 29 Levels of Fx, Fy, and Fz: a

CT and HCT, b HT
2188 Int J Adv Manuf Technol (2018) 97:2173–2192

Equally, process zone temperature was also analyzed and a decline in forces beyond the critical speed of 60 m/min is
growth in temperature at upper depth of cuts was observed due credited to thermal softening triggered by vibrations and heat
to high materials removed from the workpiece. Figure 28 pre- whereas the external heat resulted a discount of 21% in forces
sents a temperature spreading in HT at 400 μm depth of cut. in HCT. The developed model showed same behavior for Fy
and Fz in HT, as expected.
5.4 Effect of cutting speed The influence of speed on the generated heat in HT is also
examined. A growth in temperature is attained with the rise of
Several speeds are used in the FE simulations of CT, HCT, and speed, as expected (see Fig. 30).
HT, and the established results are listed in Fig. 29. Nearly
persistent levels of Fx, Fy, and Fz were detected at tested 5.5 Effect of feed rate
speeds in HCT and CT. Conversely, the extent of average
forces enlarged in HT with higher speeds and, ultimately, the The obtained FE results of forces at studied feed rates are
decline in Fx, Fy, and Fz disappeared above 70 m/min. The offered in Fig. 31. A linear growth in all force components
workpiece velocity at tested higher speed excludes separation was perceived with an increase in feed rate in studied machin-
among workpiece and insert resulted zero drop in forces. The ing processes. The volume of machined materials intensified

Fig. 31 Influence of feed rate on

Fx, Fy, and Fz in a CT and b HT
Int J Adv Manuf Technol (2018) 97:2173–2192 2189

at higher feed rate as expected, ensuing higher level of Fx, Fy, A sharp cutting edge resulted a minimum forces in all studied
and Fz. However, the results demonstrated that the level of machining processes as shown in Fig. 32. A linear growth was
forces in HT is significantly lower even at higher feed rate detected above 25 μm tool edge radius in forces for all studied
when compared to CT. A decline of 74 to 80% was detected machining processes. Yet, the tool edge radius had a prevail-
in Fx and Fy at higher feed rates. But the drop in the Fz ing importance on Fy compared to Fx and Fz in both CT and
contracted, and 58 and 50% drop was seen at 0.2 and HT.
0.3 mm/rev, respectively, due to shorter separation of insert
in vibration. Hence, HT is also a good alternative at higher 5.6 Stress analysis
feed rates and depth of cuts, with an improvement in surface
roughness and substantial decline in the cutting forces [28]. The obtained stress results revealed the same levels in HCT
Equally, a growth in temperature was noted with feed rate in and HT at full penetration for the same cutting condition. The
all studied processes, as expected. tool-workpiece contact can be categorized in four phases in
The established FE model was also used for the study of HT namely: (a) approach phase, the insert travels toward the
forces using a range of insert edge radiuses (0 to 100 μm). The workpiece; (b) engagement phase, the insert enters into the
obtained results demonstrated a prime dependency of Fy on it. workpiece material; (c) disengagement phase, the insert

Fig. 32 Cutting forces at studied

cutting-edge radiuses of insert: a
CT and b HT (V = 10 m/min; T =
300 °C; fr = 0.1 mm/rev and α =
0°)
2190 Int J Adv Manuf Technol (2018) 97:2173–2192

moved away from the chip; and (d) withdrawal phase, the surface in relevant direction resulting peak force levels in
insert completely disconnected from the chip. The spreading both cases. Additionally, the insert is partially in contact
of stress was transient in one complete cycle of vibration in with the workpiece in the withdrawal phase resulted a min-
HT as presented in Fig. 33c, d. imal drop in the tangential force component and negative
At the engagement phase in HT, the peak stress level values of Fy and Fz, as shown in Fig. 34. This denting of the
reached nearly 810 MPa resulted a lower stress magnitude workpiece yielded superior level of Fy and Fz. The level of
(by approx. 200 MPa) compared to CT. The application of Fx was 52 and 42 N, respectively, with vibration imposed
externally applied heat to the workpiece reduces its yield on the insert in radial and feed direction which is still higher
point; henceforth, lower energy is required. Similarly, the when compared to the level of Fx obtained in HT. The use
magnitude of extreme stress level dropped to 415 MPa in of elliptical vibration on the insert caused a minimal drop in
the retraction phase (see in Fig. 33). Fx, Fy, and Fz as compared to HT (see Fig. 34d, e). Minor
fluctuation in Fy was noted during the retraction stage in
5.7 2D vibration analysis XY mode of vibration.
Hence, application of tangential vibration on the cutting
In HT, vibration can be applied on the insert in feed, radial, or insert leads to a superior force reduction in HT and is more
tangential directions. In all covered experimental work in the favorable for the cutting process of Ti-15333 as 2D mode
current study, one directional vibration in the velocity direction vibration needs more complexity in machining setup.
was applied and was verified with the FE model. Also, the ob- However, the final conclusions cannot be based only on Fx,
tained results showed that vibration in the tangential direction Fy, and Fz comparison, as other factors, such as machined
had a favorable outcome on cutting forces [24]. However, a study surface quality, should also be examined.
of 2D vibrational analysis is lacking in literature using FE simu-
lations. The developed model possesses the ability to simulate
2D and 3D vibration superimposed on the insert. However, the 6 Conclusions
current work is limited to 2D vibration analysis in HT.
The obtained results showed that 1D vibrations in axial In the current study, CT, HCT, and HT are used to explore
and radial directions drive the insert to indent the machined cutting forces and process zone temperature both

Fig. 33 Calculated stress intensity in a CT; b HCT; c HT at the engagement phase; d HT at retraction phase
Int J Adv Manuf Technol (2018) 97:2173–2192 2191

Fig. 34 Forces at studied modes:

a tangential vibration, b radial
vibration, c axial vibration, d
elliptical vibration (XY-mode), e
average cutting forces

experimentally and numerically. The studied HT process is & A new hybrid-turning process is explored for cutting
an attractive tool for the industries where machinability of forces and temperature.
Ti alloys is extensively involved. The HT process can be & The level of process zone temperature is high in HT as
used to get good surface quality with minimum average compared to HCT and CT.
cutting forces even at rough cutting. The studied alloy & A substantial drop in Fx, Fy, and Fz was achieved with the
demonstrated no metallurgical effect due to the imposed hybrid turning process
vibration and heat. However, for implementation of the & The application of vibration in tangential direction result-
developed process in other grades of Ti alloys, the sensi- ed better performance compared to radial and axial modes
tivity of the alloys with temperature should be investigated of vibration in HT.
prior to shifting toward this process. Further findings of the & The application of external heat and vibration has no ad-
work are summarized below: verse effect on the machined product.
2192 Int J Adv Manuf Technol (2018) 97:2173–2192

& A superior surface quality was achieved in HT in machin- 15. Brehl D, Dow T (2008) Review of vibration-assisted machining.
Precis Eng 32:153–172
ing of Ti-15333 as compared to CT.
16. Sharman A, Bowen P, Aspinwall D, Dewes C (2001) Ultrasonic
assisted turning of gamma titanium aluminide. Rolls-Royce PLC,
Acknowledgements The authors would like to acknowledge funding re- https://books.google.com.pk/books/about/Ultrasonic_Assisted_
ceived for the current work under MAMiNa Grant. Turning_of_Gamma_Tit.html?id=KSwGMwEACAAJ&redir_esc=y
17. Astashev VK, Babitsky VI (1998) Ultrasonic cutting as a nonlinear
Publisher’s Note Springer Nature remains neutral with regard to jurisdic- (vibro-impact) process. Ultrasonics 36(1–5):89–96
tional claims in published maps and institutional affiliations. 18. Muhammad R, Roy A, Silberschmidt VV (2013) Finite element
modelling of conventional and hybrid oblique turning processes
of titanium alloy. Procedia CIRP 8:509–514
19. Muhammad R, Demiral M, Roy A, Silberschmidt VV (2013)
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