Evaluation of micro-textured tool performance in ultrasonic elliptical vibration-assisted turning of 304 stainless steel

The application of micro-textured cutting tools in various machining operations has been widely recommended as an efficient method for improving cutting performance. However, the realm of micro-textured tool utilization is rarely found in nonconventional cutting processes. This paper investigates the performance capability of a rake-faced micro-textured tool in ultrasonic elliptical vibration cutting (UEVC), which is a typical nonconventional cutting technique. A comparative experimental turning of 304 stainless steel with the micro-textured tool was performed under UEVC and conventional cutting (CC) while employing variable cutting parameters as governing factors. The cutting performance of the micro-textured tool was measured in terms of cutting forces, surface topography, chip morphology, and wear mechanism. The experimental findings revealed that the micro-textured tool outperformed the non-textured tool (NTT) in the overall machining-related outputs and the combined effect of utilizing the UEVC mechanism and cutting tool texturing techniques can significantly enhance the remarkable machining benefits of UEVC.