The influence of ultrasonic elliptical vibration amplitude on cutting tool flank wear

Abstract

In this article, the effect of vibration amplitude during ultrasonic elliptical vibration–assisted turning on cutting tool flank wear ( VBmax) and tool diffusion wear mechanism has been experimentally studied in machining of AISI 4140 hardened steel. To achieve this goal, an ultrasonic elliptical vibration–assisted turning setup was designed and manufactured. This device was then used in both ultrasonic-assisted tuning and ultrasonic elliptical vibration–assisted turning tests (i.e. one-dimensional and two-dimensional ultrasonic-assisted machining). According to the achieved results, ultrasonic elliptical vibration–assisted turning is more effective than ultrasonic-assisted tuning in reducing tool flank wear; at an amplitude of 13 μm, work velocity of 180 mm/s and feed of 0.09 mm/rev, VBmax were decreased 30.3% and 54.3%, respectively, in case of ultrasonic-assisted tuning and ultrasonic elliptical vibration–assisted turning. It was also observed that increasing the amplitude of ultrasonic vibrations reduces VBmax; at work velocity of 180 mm/s and feed of 0.09 mm/rev, the reduction of VBmax in ultrasonic elliptical vibration–assisted turning with amplitudes of 5 and 13 μm is, respectively, 39.3% and 54.3%, compared with that of conventional machining. The results also show that the application of ultrasonic vibrations weakens the cutting tool diffusion wear mechanism. This attenuation is much higher for ultrasonic elliptical vibration–assisted turning in comparison to ultrasonic-assisted tuning. Besides, the amount of attenuation in cutting tool diffusion wear mechanism decreases with increasing vibration amplitude.

Employment of ultrasonic assisted turning in the fabrication of microtextures to improve the surface adhesion of the titanium implant

“…Other machining characteristics such as residual stress and tool flank wear during UAT using elliptical vibrations presented a different behavior compared to the simple turning process and achieved more efficiency. 16,17 Zhu et al 18 studied tooltip trajectory and separation of tool and workpiece during two processes of ultrasonic-assisted turning and milling. Results of surface characteristics were compared to conventional turning and milling processes.…”

Surface roughness study of polyamide in nano-metric polishing using low-frequency acoustic energy

“…Different traditional and modern techniques are nominated to enhance surface quality of the workpiece according to cost, time, workpiece material, and surface complexities demands. In recent decades, the vibration of a tool or workpiece is known as an efficient assistant technique in conventional [1][2][3][4][5][6][7][8][9][10][11][12][13] and non-conventional [14][15][16][17][18][19][20][21][22][23][24][25][26][27][28][29][30][31] machining processes. Vibratory and ultrasonic machining are two main non-conventional polishing processes, which are based on vibration phenomenon.…”

Analysis of the cutting ratio and investigating its influence on the workpiece’s diametrical error in ultrasonic-vibration assisted turning

“…In ultrasonic-vibration assisted machining (UVAM), high-frequency vibrations are added to conventional motion of cutting tool. 1 Reduction in average cutting forces, 2 tool wear 3,4 and improvement of surface roughness 5 and heat tool effects 6 and increasing equivalent stiffness of the machining system, 7 are some of the advantages of this process. Many researcher studied influence of machining parameters on this process such as Khajehzadeh et al 8 who have worked on residual stress in ultrasonic-vibration assisted turning (UVAT) and shown percentage intensity of ultrasonic power effects on generation of residual stress.…”