Finite Element Analysis in Ultrasonic Elliptical Vibration Cutting (UEVC) During Micro-Grooving in AISI 1045

This paper compares UEVC (ultrasonic-elliptical-vibration-cutting) and a CC (conventional-cutting) process for micro-grooving in AISI 1045 via FEA (finite-element-analysis) in 2D orthogonal technique. The stress, cutting force, temperature, and residual stress have been examined. Average cutting forces in UEVC can be decreased when the velocity ratio is reduced. The average cutting forces in UEVC are declined as the vibration magnitude increases and inclined as the feed velocities and DOC increases. The stress concentration and peak cutting tool temperature in UEVC are higher than those in the CC technique because of the higher relative cutting velocity. Additionally, the peak thrust force in UEVC is larger than that in the CC technique. The main simulated residual stresses for both processes are tensile stresses, which decrease rapidly in UEVC. The compressive stress in UEVC can be more negative than that in the CC technique owing to the compression effect of the vibrated cutting tool.

Automated summary

This study compared the performance of UEVC and CC processes in micro-grooving, finding that UEVC performs better in reducing average cutting forces but has higher stress concentration and cutting tool temperatures.