Cutting Simulation And Experiments Of 3D Elliptical Vibration Cutting Device For Curved Beam

Elliptical vibration cutting can effectively reduce tool wear,cutting force and cutting heat,and is widely used in the machining of hard brittle optical crystals and ferrous metals.In three-dimensional elliptical vibration cutting,using the flexible hinge is connected to the cutting device structure is complex,there is stress concentration phenomenon at work,with curved beam as the cutting device of compliant mechanism can effectively solve these problems,the existing research only verify the feasibility of cutting device of curved beam vibration cutting,and optimize the cutting parameters.Therefore,in this paper,a three-dimensional elliptical vibration cutting device based on curved beam compliant mechanism was used to carry out single factor cutting experiments and orthogonal experiments on different materials.Through experiments,the influence of curved beam compliant mechanism cutting device on the mached surface under the condition of changing cutting parameters was studied,and the optimal surface quality cutting parameters were obtained.The finite element simulation analysis of three-dimensional elliptical vibration cutting was carried out.The simulation results show that the three-dimensional elliptical vibration cutting can effectively reduce the stress and strain in the cutting process,and the chip generated is clastic and does not pile up on the tool path.In addition,cutting force and cutting temperature decrease with the increase of frequency and amplitude.The rigidity of the curved beam cutting device in X,Y and Z directions is obtained by the static analysis,which provides a reference for the setting of vibration parameters in cutting experiments.The cutting experiment system was built by using a curved beam cutting device,a piezoelectric ceramic actuator and a piezoelectric ceramic accelerator on a common machine tool.The machine speed,cutting capacity,vibration frequency and amplitude were selected as experimental variables,and the parameters in the cutting process were changed.The single-factor cutting experiments were carried out on aluminum 6061 and 45# steel.The results of single factor experiment show that the surface roughness of Al 6061 decreases with the increase of the four experimental factors.The surface roughness of 45# steel will increase with the increase of the amount of cutting tool,and the surface roughness of 45# steel will decrease with the increase of the speed,frequency and amplitude.Orthogonal experiments were carried out on aluminum 6061 and 45# steel to obtain the three dimensional elliptical vibration cutting parameters with the minimum surface roughness.The results of range analysis and multi-factor variance analysis of orthogonal experimental data show that the influence of the four experimental factors on the surface roughness of aluminum 6061 material is 66.1%,in which the vibration frequency has the greatest influence,followed by the rotating speed,followed by the amplitude,and the cut depth has the least influence.The influence of the four experimental factors on the surface roughness of 45# steel is 93.50%,among which,the influence degree of frequency and rotation speed is far greater than the influence of the amount of cutting tool and the amplitude...