Abstract
There are many problems and physical phenomena in turning process, like machined surface quality, cutting force, tool wear, and so on. These factors and the chip shape of workpiece materials, which is an important aspect to study the mechanism of ultrasonic vibration–assisted turning, go hand in hand. This article first introduces the types and changes of chip, meanwhile the chip formation mechanism of ultrasonic vibration–assisted turning is studied and analyzed, and the turning experiments of 304 austenitic stainless steel with and without ultrasonic vibration are carried out. The difference of chip morphology between ultrasonic vibration–assisted turning and conventional turning is contrasted and analyzed from the macroscopic and microscopic point of view. The influence of process parameters on chip shape and the impact of chip shape on machining effect are also analyzed. Results indicate that when process parameters (vibration frequency, ultrasonic amplitude, and cutting parameters) are suitably selected, ultrasonic vibration–assisted turning can gain access to better chip shape and chip breaking effect than conventional turning. By contrast with conventional turning, phenomenon of serrated burr on the chip edge and the surface defects of chip in ultrasonic vibration–assisted turning have improved significantly. Moreover, it is found that superior chip morphology in ultrasonic vibration–assisted turning can be acquired under the circumstance of comparatively small cutting parameters (cutting speed, depth of cut, and feed rate); at the same time, preferable chips can also obtain ranking machining effect.
Highlights
Considering from the machining quality, removed metal amount, productivity, and capacity utilization, the turning has a wide range of application and it is an economical and practical way of machining.[1,2,3] along with extensive use of various precision instruments and components, there is an increasing demand for the machining precision and processing quality.[4]
Vivekananda et al.[5,24] made use of the finite element method to design and analyze ultrasonic vibratory tool, and studied the difference of turning 304 austenitic stainless steel with and without ultrasonic vibration; the results indicated that ultrasonic vibration– assisted turning (UAT) could reduce the cutting force and surface roughness
The chips were collected under different process parameters, and photographs were taken by a camera and super depth-of-field 3D display system
Summary
Considering from the machining quality, removed metal amount, productivity, and capacity utilization, the turning has a wide range of application and it is an economical and practical way of machining.[1,2,3] along with extensive use of various precision instruments and components, there is an increasing demand for the machining precision and processing quality.[4] various difficult-to-cut materials have gained widespread application, and the quantity of turning processing has been increased in the mechanical manufacturing,[5,6] which enable the difficulty of turning processing to be enhanced. CT includes great limitations; the ultrasonic vibration– assisted turning (UAT), which is a typical special processing method, has provided an effective approach for high-quality and high-efficiency processing of difficultto-cut materials.[7,8,9,10,11,12]
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