Cutting Chatter in Ultrasonic Elliptical Vibration Cutting and Its Influence on Surface Roughness and Tool Wear

Ultrasonic elliptical vibration cutting has a wide range of applications in the field of precision cutting of difficult-to-machine metal materials. However, due to its intermittent cutting characteristics and the weak rigidity of the horn, cutting chatter is prone to occur during its cutting process, which has an important impact on cutting surface quality and tool wear. In this paper, the rigid/viscoplastic rod model is used to simulate the horn in the ultrasonic elliptical vibration cutting device, and the influence factors of the amplitude-frequency response of the horn are analyzed. The influence of cutting speed and cutting depth on cutting chatter was studied by ultrasonic elliptical vibration cutting experiment of tungsten heavy alloy, and the influence of cutting chatter on cutting surface morphology and diamond tool wear was studied. The research shows that cutting speed will change the excitation frequency of the horn, and reasonable cutting speed can inhibit the occurrence of cutting chatter and avoid resonance of the horn. The cutting depth will affect the excitation amplitude and amplify the vibration amplitude when chatter or resonance occurs. The experimental results show that in ultrasonic elliptical vibration cutting of heavy tungsten alloy, chatter suppression can significantly improve the quality of the cutting surface and reduce the wear of diamond tools.

Automated summary

Ultrasonic elliptical vibration cutting is widely used in precision cutting of difficult-to-machine metal materials. This paper uses a rigid/viscoplastic rod model to simulate the cutting horn in the cutting device and analyzes the factors influencing the amplitude-frequency response of the horn. The influence of cutting speed and cutting depth on cutting chatter was studied through experiments, and the impact of cutting chatter on cutting surface morphology and tool wear was also investigated. The results show that the cutting speed affects the excitation frequency of the horn, and a reasonable cutting speed can prevent cutting chatter and horn resonance. The cutting depth affects the excitation amplitude and amplifies the vibration amplitude during chatter or resonance. Experimental results demonstrate that suppressing cutting chatter can significantly improve cutting surface quality and reduce diamond tool wear in ultrasonic elliptical vibration cutting of heavy tungsten alloy.