Analysis and modeling of force in orthogonal elliptical vibration cutting

Bai, Wei; Sun, Ronglei; Gao, Yuan; Leopold, Jürgen

doi:10.1007/s00170-015-7645-6

Cited by 56 publications

(28 citation statements)

References 26 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The model shows that the shear zone is divided into narrow and wide areas; this was validated by Astakhov et al [24] . Many researchers [25][26][27] used this model to predict cutting forces. As shown in Fig.…”

Section: Modelling Of Primary Shear Zonementioning

confidence: 99%

Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V

Bai

Sun

Roy

2017

International Journal of Mechanical Sciences

Self Cite

View full text Add to dashboard Cite

The aim of this paper is to propose an analytical model of chip formation for precise prediction of orthogonal cutting of Ti6Al4V. This alloy is used broadly in aerospace components; hence, prediction of thermomechanical parameters of its orthogonal cutting is crucial for various industrial applications. The suggested analytical model needs only cutting parameters and tool geometry as input; it can predict not only cutting forces but also main features of a primary shear zone and a tool-chip interface. A non-equidistant shear zone model is employed to calculate shear strains and a shear strain rate in the primary shear zone, and a simplified heat-transfer equation is used for temperature. A Calamaz-modified Johnson-Cook material model that accounting for flow softening at high strains and temperature-dependent flow softening is applied to assess shear stresses in the primary shear zone. In addition, a shear-angle solution is modified for Ti6Al4V. At the tool-chip interface, a contact length, equivalent strain and an average temperature rise are defined. Besides, the effect of sliding and apparent friction coefficients is investigated. For a sawtooth chip produced in the cutting process of Ti6Al4V, the segmentedchip formation is analysed. A chip-segmentation frequency and other parameters of the sawtooth chip are also obtained. The predicted results are compared with experimental data with the cutting forces, tool-chip contact length, shear angle and chip-segmentation frequency calculated with the developed analytical model showing a good agreement with the experiments. Thus, this analytical model can elucidate the mechanism of the orthogonal cutting process of Ti6Al4V including predictive capability of continuous and segmented chip formation.

show abstract

Section: Modelling Of Primary Shear Zonementioning

confidence: 99%

Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V

Bai

Sun

Roy

2017

International Journal of Mechanical Sciences

Self Cite

View full text Add to dashboard Cite

show abstract

“…Zhou et al 8 proposed a double-frequency EVC apparatus, which combined fast tool servo and EVC. Bai et al 9 presented the predicted model of orthogonal cutting force, which was helpful to explain the phenomena that EVC could reduce the cutting force, lower cutting temperature, and improve the surface integrity. Yin et al 10 developed a novel single-driven ultrasonic EVC device with a complex-beam horn.…”

Section: Introductionmentioning

confidence: 99%

A novel three-dimensional elliptical vibration cutting device based on the freedom and constraint topologies theory

Lin

Kong

Wang

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Aiming at the issue of the lack of the design theory for the three-dimensional elliptical vibration cutting device, a compliant mechanism with two rotations and one translation is synthesized based on the theory of freedom and constraint topologies. And a three-dimensional elliptical vibration cutting device is proposed on the basis of the compliant mechanism. The relationship between the critical speed and the length of the tool bar is analyzed. Simulation is conducted to analyze the influence of parameters on the output ellipse. Experiments are conducted to verify the validity of the elliptical vibration cutting device. The relationship between the roughness and the cutting speed is obtained. Experiments with different driving frequencies are conducted without the change of other parameters. Results show that the proposed compliant mechanism is feasible for the elliptical vibration cutting device. Compared with the common cutting, the new elliptical vibration cutting device has a better performance in the processing effect. This provides an important reference for design of the elliptical vibration cutting device.

show abstract

“…By using a quick-stop device and a vision measuring microscope, they found that ultrasonic vibrations increased shear angle which finally resulted in the reduction of toolchip contact length compared to the CT. In their further studies, Bai et al 17 developed an analytical model to predict orthogonal cutting force produced in 2D UVAT. The proposed model showed good agreement with experimental results.…”

Section: Introductionmentioning

confidence: 99%

“…In their further studies, Bai et al. 17 developed an analytical model to predict orthogonal cutting force produced in 2D UVAT. The proposed model showed good agreement with experimental results.…”

Section: Introductionmentioning

confidence: 99%

FE simulation of linear and elliptical ultrasonic vibrations in turning of Inconel 718

Lotfi

Amini

2017

Proceedings of the Institution of Mechanical Engineers, Part E:

View full text Add to dashboard Cite

Utilization of ultrasonic vibrations in turning operation is an advanced method to improve processing of materials. The aim of the present study was to develop a finite element model in order to investigate the effect of ultrasonic vibrations on machinability factors in turning of Inconel 718. Conventional turning in addition to linear and elliptical ultrasonicassisted turning were simulated and the effect of these processes on cutting forces, shear angle, chip thickness, sticky zone, and temperature distributed on tool rake face was analyzed. Besides, the experimental tests were conducted and the cutting forces have been measured to validate the simulation outputs. As a result, analysis of chip formation shows that the values higher than 45 for shear angle is achieved when elliptical vibration is added to the cutting process. Furthermore, increase of shear angle coupled with decrease of temperature on tool rake face causes the sticky zone in tool-chip contact length to be reduced compared to the conventional turning. Moreover, the influence of cutting speed on tool-chip engagement time in ultrasonic-assisted turning is simulated.

show abstract

Analysis and modeling of force in orthogonal elliptical vibration cutting

Cited by 56 publications

References 26 publications

Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V

Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V

A novel three-dimensional elliptical vibration cutting device based on the freedom and constraint topologies theory

FE simulation of linear and elliptical ultrasonic vibrations in turning of Inconel 718

Contact Info

Product

Resources

About