Abstract
Vibration assisted machining has the advantages of improved tool lifetime and chip breaking together with improved chip flushing and chip clearance. The basic principle of vibration assisted machining is the stimulation of either the cutting tool or the workpiece. Therefore the IFT developed a hydraulic based tool post actuator system making it possible to investigate the influence of superimposed frequencies on surface roughness and chip breaking. Frequencies of 0 to 30 Hz were applied while measuring the stroke of the tool post using laser interferometry. The results show that there is a significant dependency between the frequency of the tool post actuator system and the stroke value. Machining a specimen with vibration assistance showed better surface quality at higher frequencies and lower strokes. Moreover, vibration assisted machining had a significant influence on chip breaking causing eye shaped chips with comparably shorter length thus preventing continous chips completely.
Highlights
The need to improve tool lifetime and optimize machining processes in production engineering is increasing constantly
It could be shown that a distinct chip breaking was caused by the in feed direction forced vibration, which shows that the active influence on the chip cross section works properly
Compared to conventional longitudinal turning chip breaking was improved in all situations avoiding continuous chips completely
Summary
The need to improve tool lifetime and optimize machining processes in production engineering is increasing constantly. The Institute for Production Engineering and Laser Technology (IFT) sets a special focus on the issue of vibration assisted machining (VAM), which in recent times becomes a higher priority due to its special advantages These advantages include an extension of tool lifetime as well as a targeted modulation of chip breaking which goes along with improvements for the chip flushing and clearance [1] [2] [3]. The basic principle of vibration assisted machining is the stimulation of the cutting tool, especially at its resonance frequency This allows a positive supporting effect, especially for machining processes like drilling, milling and turning of brittle hard materials [4]. Products like DMG Mori Ultrasonic machine tools emerged on the market featuring ultra sonic actuated spindles [7]
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