Hybrid Energies-Assisted Cutting Technology

This chapter presents research on Laser-Ultrasonic Vibration Assisted Machining (LUVAM) and Ultrasonic and Electrical Discharge Assisted Machining of titanium alloys, focusing on integrating multiple energy fields and understanding material removal mechanisms. LUVAM combines ultrasonic vibration and laser energy in turning processes to enhance machining efficiency and surface quality. Hybrid Laser- and Ultrasonic-Assisted Machining (LUAM) significantly reduces cutting forces, particularly with ultrasonic assistance, though surface quality improvements are limited. Ultrasonic-Vibration-Laser Assisted Turning (UVLAT) shows potential in reducing cutting forces and tool wear for aluminium and magnesium alloys, albeit with possible increases in cutting temperatures and surface roughness. LUVAC benefits from laser heating to soften brittle materials, reducing cutting forces, while ultrasonic vibration extends tool life by mitigating thermal effects. Studies on composites and tungsten carbides demonstrate enhanced machining efficiency, reduced cutting forces, and improved surface quality with laser and ultrasonic vibration assistance. Validation of Ultrasonic and Electrical Discharge Assisted Milling/Turning (US-EDAM) for Ti–6Al–4V alloy machining highlights its efficient discharge gap adjustment, a significant reduction in cutting force, and improved surface integrity. US-EDAM also reduces chip adhesion, cutting heat, and surface deformation, offering potential advancements in metal processing.