Elliptical Vibration Cutting (2nd Report) - Study on Effects of Vibration Conditions

Abstract

Effects of vibration conditions on the cutting performances in the Elliptical Vibration Cutting, which has been proposed by the authors, are investigated in the present research. Cutting experiments are conducted within a scanning electron microscope in order to observe the cutting process directly. Furthermore, the roughness due to the elliptical vibration is calculated geometrically, the instantaneous relief angle is checked theoretically so that it does not become negative during cutting, and the shear angle is predicted by assuming an average friction angle and utilizing Krystof's maximum shear stress model. The experimental and analytical results show that the surface roughness decreases exponentially with an increase in the vibration frequency. It is also shown that the shear angle increases to greater than 60° and the peak cutting force decreases to less than one sixth of the force measured in the ordinary cutting, when the vibration speed is 43 times higher than the nominal cutting speed. The effects of the other vibration conditions, i.e. ratio of vertical and horizontal amplitudes and phase difference between the vertical and horizontal vibrations, are also clarified by the experiments and the analysis. © 1999, The Japan Society for Precision Engineering. All rights reserved.