Prediction Of Cutting Force In The Elliptical Vibration Assisted Turning

As a new machining method, Elliptical Vibration Cutting(EVC) has come into the stage and been widely recognized in the academic world. It enhanced our acknowledgement and understanding on ultra-precision machining technology. The unique elliptical vibration track has a lot of advantages. First of all, thanks to the periodically separation between the rake face and uncut material, it can cut hard brittle materials including glass ceramics, optical element, and silicon carbide. Second, due to friction inversion, the cutting force and cutting heat reduce significantly, which makes it easier for the drip to be eliminated. Finally, compared with traditional machining method, EVC can extend the service life of cutter and improve machining efficiency.Cutting force is one of basic physical quantity in metal cutting machining, as well as the main technical parameter in analyzing mechanism and process, and designing machine tool, cutters, and fixtures. Therefore, reliable cutting force prediction is of much significance. Analysis on cutting force helps to understand EVC temperature, stress change mechanism, and surface integrity. However, researches on EVC cutting force is not yet mature at current stage. Many scholars in and out of China put forward cutting force models, but they did not take the cutting edge blunt round radius in to consideration. In practical cutting machining, there are no completely sharp cutters. Above all, to establish a relatively perfect cutting force model should be the focus of EVC study. This paper will study the prediction of cutting force from three aspects.1. Analyze the mechanism of elliptical vibration, and explore the track, friction inversion and cutting chip generating process of EVC. Based on the split point of the cutting edge of the cutters, divide the establishment process of the cutting force into three parts: plough force model, separation cutting force model, and flank surface cutting force model. After the initial establishment of theoretical model, analyze the factors that influence the cutting force.2. Implement finite element modeling to the cutting force by ABAQUS finite element analysis software, with two-dimension EVC machining 6061 aluminum alloy. Analyze the EVC main cutting force and turning force change with different values of cutting depth, speed, vibration frequency, rake, and cutting edge blunt round radius.3. Implement cutting experiment in the ultra-precision digital cutting center and adopt PCD and 6061 aluminum alloy as the cutter and work piece material. Use piezoelectric stack actuator, piezoelectric power amplifier, capacitive displacement transducer, signal generator, multiple-spindle controller, and EVC cutting device for the debugging of the experiment system. Set appropriate cutting parameters to measure the cutting force. Adjust the parameter to observe the change of the cutting force.