6-Axis control cutting of overhanging curved grooves by means of non-rotational tool with application of ultrasonic vibrations

Abstract

This paper presents a new machining method that efficiently cuts overhanging curve grooves on wall surfaces without causing a collision between the tool and the workpiece. It also describes the development of software for 6-axis control grooving and the effect of applied ultrasonic vibrations (USV) in cutting overhanging grooves (OHG). In general, rotational tools are used to produce grooves, thus resulting in long circular arc segments at the cutting end points, as well as placing restrictions on the manufacture of grooves with continuous change in curvature, while ensuring that they do not overshoot the side clearance angle of the cutting edge with the groove. The study aims at machining OHGs presently impossible to machine by conventional methods. From the experimental results, it was found that the new machining method, which is 6-axis control cutting using a non-rotational tool with the application of USV, is capable of cutting an OHG on wall surfaces correctly.