Effect of Ultrasonic Vibration Parameters on Machining Performance Based on Tool-Workpiece Contact Ratio

Abstract

Ultrasonic assisted turning (UAT) is an efficient cutting technique for difficult-to-cut materials. In order to study the effect of vibration parameters on machining performance, tool-workpiece contact ratio (TWCR) was defined. A finite element model for ultrasonic assisted turning of Ti-6Al-4V was established. Effects of tool vibration frequency, tool vibration amplitude and workpiece cutting speed on cutting force and cutting temperature were analyzed. It is observed that both the increase in the tool vibration parameters and the decrease in the cutting speed reduce the TWCR, which in turn reduces both cutting forces and cutting temperature. By using the finite element model the appropriate tool vibration frequency, tool vibration amplitude and cutting speed can be obtained.