Vibration-assisted turning (VAT) is a technique to impose controlled external vibration on original cutting motion of turning process in order to improve part accuracy, surface quality, and tool life. In this study, the mechanics of orthogonal turning with low-frequency (less than 1000 Hz) vibration assistance is investigated. Finite element simulations are conducted to predict and compare the stresses, forces, and temperature between conventional turning (CT) and low-frequency vibration-assisted turning (LVAT). Turning experiments with vibration assistance achieved by electromagnetic actuator are conducted to validate the finite element (FE) model. The effect of vibration assistance on machining performance is quantitatively determined for three typical aerospace materials: Ti6Al4V, AISI 4340, and Al 2024 T351. It is found that LVAT is effective in reducing cutting forces, effective stresses, and cutting temperature. Compressive residual stresses are dominant in LVAT due to the added vibration. Tool wear and surface roughness in LVAT are also experimentally characterized and analyzed.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Jan 30, 2017
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