Simulation Study On Ultrasonic Vibration Assisted Cutting Of Carbon Fiber Reinforced Composites

Carbon fiber reinforced plastics/polymers(CFRP) offer excellent mechanical properties and wide applications in the aerospace, military-industrial, automotive manufacturing and other fields. However, due to the highly nonlinear and anisotropic,carbon fiber reinforced plastics/polymers are considered for its post-processing has brought great difficulties. In order to improve the machining precision and efficiency of carbon fiber composite materials, a variety of new technologies have been put forward, ultrasonic vibration assisted cutting technology is one of them. According to the tool move trajectories, the ultrasonic vibration assisted cutting can be divided into ultrasonic vibration assisted cutting and ultrasonic elliptical vibration assisted cutting. During the conventional ultrasonic vibration assisted cutting, the tool is to be applied a high frequency vibration in the feed direction, so that the rake face of the tool generates a periodic separation and uncut material. During the ultrasonic elliptical vibration cutting is in the way the auxiliary ultrasonic vibration on the basis of the auxiliary cutting is applied again in the same direction perpendicular to the feed a high-frequency vibration, so that the vibration of the tool along the elliptical locus, then during cutting the tool's rake face and flank face can be periodic separation with the workpiece, further improving the cutting performance.In this paper, using the finite element analysis software Abaqus to establish carbon fiber reinforced composites conventional ultrasonic vibration assisted cutting model and ultrasonic elliptical vibration assisted cutting model, analysis the simulation results,the main conclusions as follows:(1) Establish the carbon fiber reinforced composite ultrasonic elliptical vibration assisted cutting model, compare the simulation results with experimental results, found the error is only 15%, verified the accuracy and reliability of the model.(2) Establish the carbon fiber reinforced composites conventional ultrasonic vibration assisted cutting model with different vibration frequency and amplitude, found that increasing the frequency and amplitude of vibration is not only beneficial to reduce damage of the matrix, but also effectively reduce the cutting force.(3) The effects of vibration parameters of ultrasonic elliptical vibration assisted cutting process have been analyzed, found that increasing the amplitude on the two directions of the tool and the vibration frequency, can effectively reduce cutting forces and the damage of the matrix.(4) Compared conventional ultrasonic vibration assisted cutting simulation result and ultrasonic elliptical vibration assisted cutting simulation result, found that ultrasonic elliptical vibration assisted cutting can lead to better cutting performance, relative to the material damage to be unidirectional ultrasonic vibration cutting small, and can effectively reduce the cutting force.