Friction modeling of tool-chip interface based on shear-slip theory for vibration assisted swing cutting

Abstract

The vibration assisted swing cutting is a promising machining technology with characters of pseudo intermittent cutting and reverse friction. It can greatly extend tool life, reduce cutting forces and improve the surface accuracy of workpiece. In the cutting process, the tool-chip friction characteristics have a significant impact on the surface quality and machining accuracy of the work-piece. However, in the process of vibration-assisted swing cutting, the friction characteristics of tool-chip interface is not clear yet. In this paper, a new tool-chip friction model is proposed which takes into account the chip conversion layer is proposed based on shear slip theory. Moreover, the shear strain rate and chip particle velocity of the three friction regions of the tool-chip contact interface are described. the results show that the cutting speed increases from 75 m/min to 600 m/min, the cutting force decreases by 20 %, the thrust force decreases by 41 %, and the normal stress and shear stress decrease from 5.9 pa and 1.8 pa to 0, respectively. The increase of cutting speed leads to the increase of the temperature at the tip and the sticking at the tip. Comparing with the experimental results in existing references, the simulation results have good consistency and great prediction ability.