Abstract
Based on the theoretical analysis, an integral ultrasonic turning tool capable of compound longitudinal and bending vibration at the tool tip was designed. Considering the characteristics of the turning tool and ultrasonic vibration, the cutter head was used as the mode converter. The rigidity and machining characteristics of the tool were improved by adding a transition structure to the tool head. By means of orthogonal and single-factor analyses using a finite element simulation, the sensitivity of the tool cutter head to the resonance frequency was examined: the tool tip angle β> the cutter head inclination angle θ> the main relief angle α0> the minor cutting edge length l1. The influence of the geometrical characteristics of the tool on the longitudinal-bending component ratio i was analyzed using the single-factor analysis method, and the geometrical angle of cutter head is modified accordingly. Finally, better resonance effect and longitudinal-bending component ratio i were obtained. An ultrasonic-assisted cutting test for an aluminum alloy was carried out with the designed turning tool, and the characteristic microscopic surface topography akin to fish scale was obtained, which verified the rationality and feasibility of the design.
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