Papers by Keyword: Ultrasonic Vibration-Assisted Cutting

Abstract: Ultra-precision ultrasonic vibration-assisted cutting (UVC) with polycrystalline diamond (PCD) tool refers to the cutting with certain amplitude and high frequency tool vibration, which can definitely reduce the cutting forces and tool wear when compared with the conventional cutting. However, in the actual cutting process, the tool vibration direction is not strictly in accordance with the designed cutting direction based on the manufacturing dimension and installation accuracy error of the vibration device. It will result in an inclined cutting angled with the linear direction. The inclination angle leads to periodical grooves on the machined surface, therefore affecting the quality of machined surface. In addition, the inclined vibration cutting will also lead to an increase in cutting forces, thus exacerbating the PCD tool wear. This paper has analyzed the influence of inclined vibration on the roughness of machined surface. A finite element (FE) simulation model of inclined linear vibration cutting has also been set up to analyze the variations of cutting forces with different inclination angle, so as to explore the mechanism of tool wear. Moreover, ultra-precision ultrasonic vibration-assisted cutting (UVC) experiments with different inclination angle have been carried out. The machined surface and PCD tools have been investigated. Combining with the theoretical analysis, this work has concluded that inclined vibration will increase the roughness of machined surface as well as exacerbate the PCD tool wear. The effective techniques have been proposed to improve the surface quality and reduce the tool wear by reducing the inclination angle of vibration and with carbon atmosphere.

Abstract: Traditionally, single point diamond turning (SPDT) can not process ferreous metals because of acute tool wear. Ultrasonic vibration-assisted cutting(UVC) provides a promising solution for the problem. In this paper, for the aim of directly obtaining mirror surface on die steels, UVC method was used combining with SPDT process. Experiments were carried out on an ultra precision turning machine, cutting parameters and vibration parameters were well-chosen, and two kind of feed rates, two kinds of prevailing die steels were experimented. Mirror surfaces were successfully achieved on face turning, with the best roughness of Ra16.6nm. And the surface roughness, surface texture and tool wear in machining process were discussed.

Abstract: Although titanium is a very useful material and becoming more in demand, we are faced with difficulties in machining the material. By applying ultrasonic vibration to the tool tip, interrupted cutting can be applied. Using ultrasonic vibration-assisted cutting of titanium alloy, we succeeded in reducing the cutting force. This technology enables us to improve tool wear and surface roughness of the workpiece. In regards to cutting fluid supply methods, it was found that semi-dry cutting was the most suitable for ultrasonic vibration-assisted cutting of titanium alloy.