High-frequency electrically-assisted turning: Application to aluminium

The manufacturing of engineering alloys has been developing over the years to meet the increasing demand for more efficient techniques and high-quality products. The electrically and ultrasonically-assisted manufacturing processes have been gaining attention due to their potential in reducing energy consumption and improving machined surface qualities. This research explores the capability of the combination of these techniques using continuous and pulsed currents at high frequencies to improve the machinability of metals. Electric current is applied to the workpiece through the cutting tool to harness the electroplastic effect with local softening due to high current density at the cutting zone. The electric current was delivered into the workpiece in continuous and in pulses at different peak current values, with low cutting speed and feed rate. Ultrasonic vibrations were added to amplify the current frequency and reduce the cutting force. Results showed a reduction in cutting force and surface roughness when electric current was applied in pulses at a high peak current. The study showed that electrically-assisted turning has great potential to help improve the machinability of materials.