Effect of lubrication and cutting parameters on ultrasonically assisted turning of Inconel 718
TL;DR: In this paper, the authors further developed the finite element (FE) model of ultrasonically assisted turning discussed in Mitrofanov et al. This model is used to study the effect of cutting parameters (such as the cutting speed, depth of cut and feed rate) and influence of lubrication on various features of two turning techniques, including cutting forces and chip shapes.
About: This article is published in Journal of Materials Processing Technology.The article was published on 2005-05-15. It has received 82 citations till now. The article focuses on the topics: Chip formation & Lubrication.
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01 Jul 2008-Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology
TL;DR: In this paper, the basic kinematic relationships for 1D and 2D VAM (circular/elliptical tool path) are described and the periodic separation between the tool rake face and uncut material, characteristic of VAM, is related to observed reductions in machining forces and chip thickness.
Abstract: Vibration-assisted machining (VAM) combines precision machining with small-amplitude tool vibration to improve the fabrication process. It has been applied to a number of processes from turning to drilling to grinding [9] , [36] . The emphasis on this literature review is the turning process where VAM has been applied to difficult applications such as diamond turning of ferrous and brittle materials, creating microstructures with complex geometries for products like molds and optical elements, or economically producing precision macro-scale components in hard alloys such as Inconel or titanium. This review paper presents the basic kinematic relationships for 1D (linear vibratory tool path) and 2D VAM (circular/elliptical tool path). Typical hardware systems used to achieve these vibratory motions are described. The periodic separation between the tool rake face and uncut material, characteristic of VAM, is related to observed reductions in machining forces and chip thickness, with distinct explanations offered for 1D and 2D modes. The reduced tool forces in turn are related to improvements in surface finish and extended tool life. Additional consideration is given to the intermittent cutting mechanism and how it reduces the effect of thermo-chemical mechanisms believed responsible for rapid wear of diamond tools when machining ferrous materials. The ability of VAM to machine brittle materials in the ductile regime at increased depth of cut is also described.
657 citations
TL;DR: In this paper, the UVC mechanism is influenced by three important parameters: tool vibration frequency, tool vibration amplitude and workpiece cutting speed that determine the cutting force, which in turn reduces both cutting force and tool wear, improves surface quality and prolongs tool life.
Abstract: The ultrasonic vibration cutting (UVC) method is an efficient cutting technique for difficult-to-machine materials. It is found that the UVC mechanism is influenced by three important parameters: tool vibration frequency, tool vibration amplitude and workpiece cutting speed that determine the cutting force. However, the relation between the cutting force and these three parameters in the UVC is not clearly established. This paper presents firstly the mechanism how these parameters effect the UVC. With theoretical studies, it is established that the tool–workpiece contact ratio (TWCR) plays a key role in the UVC process where the increase in both the tool vibration parameters and the decrease in the cutting speed reduce the TWCR, which in turn reduces both cutting force and tool wear, improves surface quality and prolongs tool life. This paper also experimentally investigates the effect of cutting parameters on cutting performances in the cutting of Inconel 718 by applying both the UVC and the conventional turning (CT) methods. It is observed that the UVC method promises better surface finish and improves tool life in hard cutting at low cutting speed as compared to the CT method. The experiments also show that the TWCR, when investigating the effect of cutting speed, has a significant effect on both the cutting force and the tool wear in the UVC method, which substantiates the theoretical findings.
276 citations
Cites background from "Effect of lubrication and cutting p..."
...Extensive theoretical research [12–16], simulation [17] and experimental results [8–12,19,20] for the UVC method mention that the lower cutting force is due to a considerable reduction of friction between the tool and the workpiece [17,19] and the separating or pulse cutting characteristic of the tool [12–14,18,21]....
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TL;DR: In this article, a systematic in-depth analysis of diversified aspects of ultrasonic application in metal joining and processing including its limitations, future prospects and assessments are classified and discussed, and detailed state-of-the art, experimentation and progresses of the ultrasonic vibrations and its applications in the above areas are comprehensively examined, evaluated and presented for exhaustive understandings of its physical mechanism.
177 citations
TL;DR: In this article, the authors provide a comprehensive discussion and review about some key aspects of UVA machining such as cutting kinematics and dynamics, effect of workpiece materials and wear of cutting tools, involving a wide range of materials including metal alloys, ceramics, amorphous and composite materials.
Abstract: Ultrasonic vibration-assisted (UVA) machining is a process which makes use of a micro-scale high frequency vibration applied to a cutting tool to improve the material removal effectiveness. Its principle is to make the tool-workpiece interaction a microscopically non-monotonic process to facilitate chip separation and to reduce machining forces. It can also reduce the deformation zone in a workpiece under machining, thereby improving the surface integrity of a component machined. There are several types of UVA machining processes, differentiated by the directions of the vibrations introduced relative to the cutting direction. Applications of UVA machining to a wide range of workpiece materials have shown that the process can considerably improve machining performance. This paper aims to provide a comprehensive discussion and review about some key aspects of UVA machining such as cutting kinematics and dynamics, effect of workpiece materials and wear of cutting tools, involving a wide range of workpiece materials including metal alloys, ceramics, amorphous and composite materials. Some aspects for further investigation are also outlined at the end.
113 citations
Cites background from "Effect of lubrication and cutting p..."
...[6] 1D Cutting force reduction was up to 20%–50%; chips were thinner by about 15%; temperature in cutting region was lower...
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TL;DR: In this article, an experimental study and computational (finite element) model of both CT and UAT forces acting on the cutting tool in UAT are studied, and their dependence on vibration amplitude, frequency and vibration direction as well as on cutting parameters, such as feed rate and cutting speed, are investigated.
102 citations
References
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TL;DR: In this paper, a cumulative-damage fracture model is introduced which expresses the strain to fracture as a function of the strain rate, temperature and pressure, and the model is evaluated by comparing computed results with cylinder impact tests and biaxial (torsion-tension) tests.
4,744 citations
Book•
06 Jul 2000
TL;DR: The most up-to-date in the field of metal machining is "Metal Machining: Theory and Applications" as mentioned in this paper, which provides in-depth discussion of the theory and application of machining at an advanced level.
Abstract: Metal machining is the most widespread metal-shaping process in the mechanical manufacturing industry. World-wide investment in metal machining tools increases year on year - and the wealth of nations can be judged by it. This text - the most up-to-date in the field - provides in-depth discussion of the theory and application of metal machining at an advanced level. It begins with an overview of the development of metal machining and its role in the current industrial environment and continues with a discussion of the theory and practice of machining. The underlying mechanics are analysed in detail and there are extensive chapters examining applications through a discussion of simulation and process control. "Metal Machining: Theory and Applications" is essential reading for senior undergraduates and postgraduates specialising in cutting technology. It is also an invaluable reference tool for professional engineers. Professors Childs, Maekawa, Obikawa and Yamane are four of the leading authorities on metal machining and have worked together for many years. Of interest to all mechanical, manufacturing and materials engineers Theoretical and practical problems addressed
501 citations
TL;DR: In this article, the effects of edge preparation of the cutting tool (round/hone edge and T-land/chamfer edge) upon chip formation, cutting forces, and process variables (temperature, stress, and strain) in orthogonal cutting as determined with finite element method (FEM) simulations.
317 citations
TL;DR: In this article, the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer was investigated using finite element code Abaqus, and the authors showed that residual stress is sensitive to the friction condition of the toolchip interface.
212 citations
TL;DR: The results of the research in ultrasonically assisted machining are presented in this paper, where turning of modern aviation materials was conducted with ultrasonic vibration applied in the feed direction using an autoresonant control system.
188 citations