Research On Elliptic Vibration Cutting Mechanism Based On Finite Element Method

With the rapid development of micro nano manufacturing technology, precision mold with micro structure surface are used more widely. Precision mold are usually worked in some conditions of harsh conditions, which required more stringent performance. However, the precise mould base material most are confined to some non-ferrous metal and coating materials, this is because there is no efficient method for the processing of ideal material has the characteristics of high strength and high hardness. In order to meet the demand, a2D vibration cutting (elliptical vibration cutting) technology is widely concerned by the scholars, elliptical vibration cutting has inherited the advantage of traditional one-dimensional vibration cutting that the intermittent contact between the tool and workpiece surface and chip avoid the tool flank and the machined surface contact most, improve the machined surface quality and tool life. But the study of elliptical vibration cutting is still at the initial stage, whose application to practical production still needs further research and practice constantly.Based on the analysis of the research status of elliptical vibration cutting on the simulation research, simulation of elliptical vibration cutting by using the finite element software and the main work is summarized as follows:1. The paper introduces the principle of cutting elliptical vibration cutting technology, tool path mechanism of the elliptical formation is expounded, and the cutting force model is appropriate, analysis of the process of theoretical error during the cutting process, the relationship curves between the speed coefficient K and the theory errors.2. The2D finite element model is established by finite element software to apply in the elliptical vibration cutting. The simulation result was compared with the same process condition of cutting experiment to verify the correctness of the model.3. Influence of process parameters of2D finite element model with the construction of the elliptical vibration cutting on cutting force and cutting temperature was simulated, the relevant rules:improve the vibration frequency, amplitude or appropriate to reduce the feed speed are beneficial to reduce cutting force and cutting temperature, and in combination with its cutting mechanism the cause of these rules. The Al6061, brass C37700, MP35N nickel alloy and stainless steel304were studied, indirectly confirmed the inherent advantage of elliptical vibration cutting of difficult machining materials.4. The formation mechanism of the surface residual stress of workpiece was studied, using the finite element software simulated ordinary cutting, one-dimensional vibration cutting and elliptical vibration cutting of the machined surface residual stress distribution. As the result, compared with other two kinds of cutting modes, elliptical vibration cutting forms surface compressive residual stress, which has maximum absolute value, and the workpiece surface within a certain depth has an obvious distribution.