Abstract

High-speed ultrasonic vibration cutting has been proven to be effective in prolonging tool life, as well as reducing cutting force and cutting temperature at certain cutting speeds, which is higher than both the critical cutting speed of traditional ultrasonic vibration cutting and the range of conventional high-speed cutting in recent research. However, the surface topography results from the periodic sinuous tool vibration trajectory, and its influence on machined surface roughness, remains unclear. Therefore, in this article, the modeling and analysis of the surface topography and roughness are developed first. Then, simulations conducted through MATLAB calculations, SOLIDWORKS modeling, and cutting experiments are conducted to investigate the influences of the feed rate and the phase shift between the adjacent tool trajectories on the surface roughness. The results indicate that optimal surface roughness can be obtained under the conditions of a small feed rate (0.005 mm/r) and a phase shift of 180°. In this condition, the surface finish can reach Ra < 0.4 μm and realize finishing machining. In addition, compared with conventional cutting, high-speed ultrasonic vibration cutting can achieve the same quality at a cutting speed two times that of conventional cutting. Consequently, a better surface quality can be obtained through high-speed ultrasonic vibration cutting, due to the decrease of surface roughness compared with that of conventional cutting.

摘要

事实证明，高速超声振动切削可有效延长刀具寿命，并在某些切削速度下降低切削力和切削温度，这既高于传统超声波振动切削的临界切削速度，又高于常规切削范围高速切削的最新研究。但是，表面形貌是由周期性的弯曲刀具振动轨迹产生的，其对机加工表面粗糙度的影响仍然不清楚。因此，本文首先对表面形貌和粗糙度进行建模和分析。然后，通过MATLAB计算，SOLIDWORKS建模，进行切削实验以研究进给速度和相邻刀具轨迹之间的相移对表面粗糙度的影响。结果表明，在小进给率（0.005 mm / r）和相移180°的条件下可以获得最佳的表面粗糙度。在这种情况下，表面光洁度可以达到R a <0.4μm，实现精加工。另外，与常规切割相比，高速超声振动切割可以以常规切割的两倍的切割速度获得相同的质量。因此，由于与常规切割相比表面粗糙度降低，因此可以通过高速超声振动切割获得更好的表面质量。