Modeling of cutting forces in 1-D and 2-D ultrasonic vibration-assisted milling of Ti-6Al-4V

To meet the modern demands for lightweight construction and energy efficiency, hard-to-machine materials such as ceramics, superalloys, and fiber-reinforced plastics are being used progressively. These materials can only be machined with great effort using conventional machining processes due to the high cutting forces, poor surface qualities, and the associated tool wear. Vibration-assisted machining has already proven to be an adequate solution in order to achieve extended tool lives, better surface qualities, and reduced cutting forces. This paper presents an analytical force model for longitudinal-torsional vibration-assisted milling (LT-VAM), which can predict cutting forces under intermittent and non-intermittent cutting conditions. Under intermittent cutting conditions, the relative contact ratio between the rake face and the sliding chip is utilized for modelling the shearing forces. Ploughing forces and shearing forces under non-intermittent cutting conditions are calculated by using an extended macroscopic friction reduction model, which can predict the reduced frictional forces under parallel and perpendicular vibration superimposition. The force model was implemented in MATLAB and can predict cutting forces without using any experimental vibration-assisted milling (VAM) data input.

Z-Map Based Cutting Force Prediction for Elliptical Ultrasonic Vibration-Assisted Milling Process

Elliptical ultrasonic vibration-assisted milling (EUVAM) adds high-frequency vibration to conventional milling (CM) to realize high-frequency intermittent milling. It has broad application prospects in the processing of difficult-to-cut materials such as titanium alloys, superalloys and hard and brittle materials. To reveal the mechanism of the highly intermittent cutting nature in EUVAM, according to the motion relationship between cutting edge and workpiece and the Z-map model of the workpiece, a method and its algorithm for calculating undeformed cutting thickness and thus the cutting force in EUVAM are proposed. The simulation results show that EUVAM can improve the actual cutting speed when compared with CM, and the proportion of idle cutting time will directly determine the intermittent degree of the milling process. The experiment of EUVAM is performed to verify the correctness of the proposed cutting force model, and the impact of spindle speed on the cutting force in EUVAM is also analyzed.

Modeling of residual stresses by correlating surface topography in machining of AISI 52100 steel

The residual stresses could affect the ability of components to bear loading conditions and also the performance. The researchers considered workpiece surface as a plane and ignored the effect of surface topography induced by the intermittent cutting process when modeling residual stresses. The aim of this research develops an analytical model to predict workpiece residual stresses during intermittent machining by correlating the effect of surface topography. The relative motions of tool and workpiece are analyzed for modeling thermal-mechanical and surface topography. The influence of dynamic cutting force and thermal on different positions of surface topography is also considered in analytical model. Then the residual stresses model with the surface topography effect can be developed in intermittent cutting. The analytical models of dynamic cutting force, surface topography and residual stresses are verified by the experiments. The variation trend of evaluated values of the residual stress of workpiece is basically consistent with that of measured values. The compressive residual stress of workpiece surface in highest point of the surface topography are higher than that in the lowest point.

Analytical Modeling of Machining Forces and Friction Characteristics in Ultrasonic Assisted Turning Process

Intermittent cutting characteristics of Ultrasonic assisted turning (UAT), Compared to conventional turning (CT), has shown a significant enhancement in the machinability of hard-to-cut materials. The enhancement in machinability is associated with machining forces and friction characteristics of the process. The present article covers an analytical approach to predict the output responses such as machining forces and friction characteristics in UAT and CT processes. Specific cutting energy (SCE) for a particular work-piece material was considered to predict the output responses. The predictions were made by considering the conventional machining theories. Experiments for the UAT and the CT of SS 304 were carried out to validate the predicted model. The results from the analytical model showed that the shear angle increases and the tool-workpiece contact ratio (TWCR) decrease with an increase in amplitude and frequency of vibration. The results obtained from the analytical model were found to be in close agreement with the experimental ones, with an approximate error of 2-20%.

Effect of Cutting Parameters on Chips and Burrs Formation With Traditional Micromilling and Ultrasonic Vibration Assisted Micromilling

In the traditional micromilling(TMM) of Inconel718 alloy, due to the influence of material plasticity and size effect, relatively large burr will be produced. In order to solve the burr problem in micromilling, ultrasonic vibration in feed direction is applied to the workpiece to complete vibration cutting. Combined with trajectory simulation and cutting experiment, the burr formation mechanism of TMM and ultrasonic vibration assisted micromilling(UVAMM) was studied. The results show that when the ratio of amplitude(A) to feed per tooth(ƒz) is greater than 0.5, continuous cutting changes to intermittent cutting. Compared with TMM, UVAMM improves chip breaking ability, facilitates the propagation of burr crack and effectively inhibits the formation of burr. However, due to the influence of cutting edge radius, A/ƒz should be set larger. When the chip breaking condition is reached, the burr shape is usually tearing or flocculent. Under the conditions of low speed(n), large ƒz and large A, the burr suppression is more obvious.

Effect of Vibration Direction of Ultrasonic Vibrating Cutting Edge on Internal Stress Fluctuation of Workpiece

The aim of this study is to investigate the dynamic phenomenon of ultrasonic vibration-assisted cutting by utilizing a stress distribution visualization system. The vibrating cutting-edge is considered to be a cause of dynamic changes in the cutting force at ultrasonic frequencies. However, many researchers have explained the effect of ultrasonic vibration-assisted cutting by evaluating the time-averaged cutting force, because existing dynamometers are unable to measure the dynamically changing cutting force at ultrasonic frequencies. There are some reports that the vibration direction of cutting edge strongly affects tool wear. However, in practical ultrasonic cutting, the vibration of the cutting edge has yet to be measured in a production environment. In this study, the instantaneous stress distribution on the workpiece was visualized by a photoelastic method that combines a pulsed laser emission synchronized with tool vibration. The developed photographic system can capture 360 frames in one ultrasonic vibration period. The dynamic cutting force was calculated by Flamant’s stress distribution theory. It was experimentally confirmed that the stress distribution under vibration-assisted conditions showed periodical changes synchronized with vibration. Because these results are compatible with well-known vibration-cutting theories, the imaging system was able to show the periodic changes in stress distribution in the ultrasonic frequency band. This indicates that the dynamic change in cutting force during the ultrasonic vibration period affects intermittent cutting conditions. In this report, the vibration direction was adjusted from −9.5° to +9.5° along the cutting direction. When the tool moved in upwards for the cutting phase and downwards for withdrawal phase, the stress distribution was continuously observed over one tool vibration period; no intermittent cutting was observed. The locus of the cutting force vector was affected by the ultrasonic vibration direction and rake angle of the cutting tool. A negative rake angle showed that the direction of the cutting force vector shifted toward the workpiece side near the most advanced position of the cutting edge.

Modeling of Cutting Forces in 1-D & 2-D Ultrasonic Vibration Assisted Milling of Ti-6Al-4V

To meet the modern demands for lightweight construction and energy efficiency, hard-to-machine materials such as ceramics, superalloys and fiber-reinforced plastics are being used progressively. These materials can only be machined with great effort using conventional machining processes due to the high cutting forces, poor surface qualities, and the associated tool wear. Vibration-assisted machining has already proven to be an adequate solution in order to achieve extended tool lives, better surface qualities and reduced cutting forces. This paper presents an analytical force model for longitudinal-torsional vibration-assisted milling (LT-VAM), which can predict cutting forces under intermittent and non-intermittent cutting conditions. Under intermittent cutting conditions, the relative contact ratio between the rake face and the sliding chip is utilized for modelling the shearing forces. Ploughing forces and shearing forces under non-intermittent cutting conditions are calculated by using an extended macroscopic friction reduction model, which can predict the reduced frictional forces under parallel and perpendicular vibration superimposition. The force model was implemented in MATLAB and can predict cutting forces without using any experimental vibration-assisted milling (VAM) data input.

Equipment and materials for shock-intermittent cutting

The article considers the shock-intermittent processing method, which is used for cutting blind threads M12x1.5 in nuts made of steel grade X18N9T. Compared to the conventional method, it allows increasing the processing productivity; the durability of the thread taps has increased to 300 holes (with manual thread cutting, the durability of the taps is 100 holes). The method allows mechanizing labor-intensive threading operations. The optimal conditions of processing by this method are determined based on ensuring sufficient strength of the cutting wedge of the tool under repeated loading and, at the same time, creating the most intense impact on the material of the cut layer of the workpiece. The destruction of the processed material on impact most easily occurs at critical deformation rates, which, for instance, equal 60 m/s for corrosion-resistant steel. This leads to an overestimation of the impact pulse values, and consequently, chipping of the cutting edges of the tool. Therefore, for these processing conditions, there is an optimal value of the pulse load transmitted by the spindle to the tool. For threads M10 and M12 with pitches of 1.25 and 1.5 in parts made of steel grades X18N10T, the best results are achieved at loads corresponding to the increment of the dynamic moment of the driven bushing with the tool. At high pulse loads, the durability of the working tool is sharply reduced, and at lower loads, the cutting performance is reduced. One of the positive features of shock-intermittent cutting is the presence of breaks that facilitate the operation of the cutting wedge due to the better penetration of the coolant. Therefore, shockintermittent cutting is carried out at more intensive modes than conventional continuous cutting. However, the tool life does not decrease as a result, but even increases. The relative length of the cutting area, determined by the angle, should be chosen based on the fact that the temperature in the cutting area does not have time to reach its steady value, equal to the cutting temperature during the normal long-duration cutting, carried out continuously.

Geklebte Keramiken im unterbrochenen Schnitt/Adhesive bonded ceramics in intermittent cutting – Investigation of circular sawing of grey cast iron with adhesively bonded ceramic teeth

Der Beitrag beschreibt, wie Verbundkreissägeblätter mit geklebten keramischen Zähnen hergestellt wurden. Dafür wurden die Keramiken, aufbauend auf bisherigen eigenen Untersuchungen, mittels Laseroberflächenstrukturierung vorbehandelt und mit einem modifizierten Lötautomaten verklebt. Anschließend wurden die Werkzeuge geschliffen und in einem Modellversuch auf ihre Funktionsfähigkeit und Einsatzverhalten untersucht.   This article presents the manufacturing of adhesively bonded circular saw blades with ceramic teeth. Based on own previous investigations, the ceramic surfaces were treated by laser surface texturing and adhesively bonded by a modified brazing machine. Then the tools were grinded and functioning and behavior were validated in a model experiment.