Use of hard material like stainless steel, Inconel 718 etc. has been increased in many industries like aerospace sector, defense sector etc. It has been noticed that hard material are very difficult to cut in conventional turning process. Ultrasonic assisted turning process found to be a good alternative process to cut hard material by giving vibration to the tool and hence it acts as intermittent cutting which leads to increase tool life. In the present work FEM analysis has been done for Horn (acts as amplifier as well as tool holder) using mild steel material to know the frequency and amplitude of vibration at the output end by ANSYS® software and has been manufactured. Experimental investigation has been carried out for both conventional turning process and Ultrasonic assisted turning process to know the various process parameter effects on cutting forces and surface finish generated. From the experiment it has been found that Ultrasonic assisted turning improves both cutting force and surface finish. Finally Gray Taguchi method adopted for optimize both cutting force and surface finish (Multi objective optimization) to get the best combination of process parameters.
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