Ultrasonically assisted turning of aviation materials: simulations and experimental study

Ultrasonically assisted turning of modern aviation materials is conducted with ultrasonic vibration (frequency f approximate to 20 kHz, amplitude a approximate to 15 pm) superimposed on the cutting tool movement. An autoresonant control system is used to maintain the stable nonlinear resonant mode of vibration throughout the cutting process. Experimental comparison of roughness and roundness for workpieces machined conventionally and with the superimposed ultrasonic vibration, results of high-speed filming of the turning process and nanoindentation analyses of the microstructure of the machined material are presented. The suggested finite-element model provides numerical comparison between conventional and ultrasonic turning of Inconel 718 in terms of stress/strain state, cutting forces and contact conditions at the workpiece/tool interface. (C) 2004 Elsevier B.V. All rights reserved.