Influence on surface characteristics generated in Low Frequency Vibration Cutting

Abstract

LFV is one of effective machining technologies to break long and continuous chips in the turning process. LFV technology stands for low frequency vibration cutting. Vibration in the tool feed direction is applied in LFV and it is synchronously controlled with the spindle rotation. When the machined surface is focused on, characteristic surface patterns are formed in LFV turning process because of the tool vibration in feed direction. In this paper, a simulation technique to visualize the surface profile generated on the cutting process with LFV was developed. By visualizing the surface shape and contour shape, it is possible to clarify its features and calculate the surface roughness and roundness. During LFV operation, unlike conventional turning with constant feed rate, a cutting edge moves on the machined surface while vibrating in feed direction; hence characteristic patterns are formed by the uncut portion corresponding to the crossing cutter marks depending on the vibration conditions. The influence of such characteristic patterns on the surface roughness and the contour profile was clarified in detail. In addition, the vibration condition which can minimize roundness of the machined object was identified by using the developed simulation. Then the contour profile of the machined parts during LFV operation could be controlled.

Tool design for low-frequency vibration cutting on surface property

“…Furthermore, vibration conditions were reported to influence the texture of machined surfaces (Okamura et al, 2006). Miyake et al (2020) confirmed that adjusting the amplitude ratio influences the surface roughness, which can be improved by changing the trajectory of the tool as the parameter is optimized (Miyake et al, 2020).…”

“…Simulations were utilized to demonstrate the machined surface properties by plotting the tool trajectory based on the tool nose R, frequency ratio, and amplitude ratio (Miyake et al, 2020). The tool path can be calculated as follows:…”

“…The necessity for optimizing the amplitude according to the characteristics of the work material was discussed in a previous study (Paulsen et al, 2020). A practical range was reported in terms of chip breakup and its effect on the surface roughness (Miyake et al, 2020).…”

“…Additionally, roundness can be improved by adjusting the frequency ratio (Miyake et al, 2020). Thus, to an extent, the surface roughness and roundness can be improved by optimizing the amplitude and frequency ratios.…”