SURFACE ROUGHNESS AND GEOMETRIC PRECISION IN ULTRASONIC VIBRATION-ASSISTED TURNING OF HARDENED 9CrSi ALLOY STEEL

Trung Hoang Kien (), Trieu Quy Huy and Nguyen Duc Toan
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Trung Hoang Kien: Faculty of Mechanical Engineering, Thainguyen University of Technology, Thainguyen 250000, Vietnam
Trieu Quy Huy: Faculty of Mechanical Engineering, University of Economics — Technology for Industries, Hanoi 100000, Vietnam
Nguyen Duc Toan: School of Mechanical Engineering, Hanoi University of Science and Technology, No. 1, Dai Co Viet Rd., Hanoi 100000, Vietnam

Surface Review and Letters (SRL), 2025, vol. 32, issue 08, 1-13

Abstract: This study investigates the application of ultrasonic vibration-assisted turning (UAT) in machining hardened 9CrSi alloy steel, with a hardness range of 60-62 HRC. The research focuses on the effects of ultrasonic vibration frequency and amplitude on surface roundness and cylindrical accuracy during the turning of a cylindrical workpiece with dimensions of 63mm in diameter and 40mm in length. A piezoelectric transducer (PZT) operating at a frequency of 28kHz and an amplitude range of 5–10 μm was employed to generate the ultrasonic vibrations. Experimental results were analyzed using a 2-sample t-test to evaluate the effects of UAT. The findings show a significant enhancement in surface quality, with surface roughness reduced by approximately half compared to conventional turning (0.705 μm vs 1.302 μm). Additionally, UAT achieved superior geometric precision, with roundness and cylindricity errors reduced by about two-thirds and one-half, respectively, compared to conventional turning (roundness error: 0.00556mm vs 0.01361mm; cylindricity error: 0.026mm vs 0.046mm). The ultrasonic vibrations facilitated the formation of shorter, intermittent chips, reducing the risk of surface scratching and contributing to a longer tool life. Furthermore, UAT demonstrated the potential to operate without lubrication, offering both economic and environmental benefits by reducing costs and minimizing pollution. These results highlight the potential of UAT to revolutionize machining processes by enhancing efficiency, precision, and sustainability. However, it is important to note that while UAT shows promising results, further studies are needed to explore its limitations, such as the impact on tool wear over extended periods of use and the scalability of the process for industrial applications.

Keywords: Ultrasonic vibration-assisted turning (UAT); hardened 9CrSi alloy steel; surface roughness; cylindricity; lubrication-free machining (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X25400141

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