Finite element simulations of ultrasonically assisted turning

Ultrasonically assisted turning is a promising machining technology, where high frequency vibration (f≈20 kHz) with an amplitude a≈10 μm is superimposed on the movement of the cutting tool. Ultrasonic turning yields a noticeable decrease in cutting forces, heat and noise radiation, as well as a superior surface finish, comparing to the conventional machining technology. The present study utilizes both experimental techniques and numerical (finite element) simulations to analyze the microstructural processes at the cutting tool–chip interface. High-speed filming of the chip–tool interaction zone during cutting and microstructural and nanoindentation analyses of the machined surfaces are used to compare process zones and deformation processes for both conventional and ultrasonically assisted technologies. The suggested finite-element (FE) model, which utilizes MSC Marc/Mentat general FE code, provides a transient analysis for an elasto-plastic material, accounting for the frictionless contact interaction between a cutter and workpiece as well as material separation in front of the cutting edge. A detailed analysis of cutting for a single cycle of ultrasonic vibration is carried out for isothermal conditions. Differences between conventional and ultrasonic turning in stress distribution in the process zone and contact conditions at the tool/chip interface are investigated.