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Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

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Abstract

In the 2D-Vibration Assisted Cutting (2D-VAC) method, the cutting tool shakes in a 2-dimensional approach because of superimposed high-frequency modulation. This high-frequency modulation effect creates a displacement at a tiny scale of micrometers and causes an escalation in the resultant cutting speed. Consequently, 2D-VAC has superior advantages compared to traditional cutting (TC). This manuscript describes research on 2D-VAC that focuses on modeling cutting forces (mathematical model) and finite element analysis (FEA) results. The FEA results are focused on the von Mises stress, plastic strain, cutting force, cutting temperature, and residual stress. In addition, an experiment for the chip formation, micro-structure layer, and micro-hardness was also analyzed in this study. According to the modeling results, the cutting force has a comparable pattern to the FEA results. The stress contour result confirms that the 2D-VAC method has lower stress than that in the TC method during tool retraction mode. Additionally, the plastic strain in the 2D-VAC method can be higher than that in the TC method. According to the temperature results, the peak temperature in the 2D-VAC could be higher than that in the TC method. The residual stress shows that there is a compressive effect. Thus, the compressive stress is higher than that in the TC method. Micro-hardness results confirmed that there is not too much change from the original surface in the 2D-VAC method. The result of micro-structure morphology also confirmed that there is a significant shear deformation flow in case of the TC method, although less occurs in the 2D-VAC method.

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Abbreviations

x e(t):

The tool movement in x-direction at the CC-point as function of time

y e(t):

The tool movement in y-direction at the CC-point as function of time

a m :

The elliptical locus magnitude in x-direction

b m :

The elliptical locus magnitude in y-direction

f v :

The frequency vibration of the tool movement in Hz

φ :

The phase difference between cosine wave in radian

t :

The time in second

V c :

The constant cutting speed of the cutting tool in μm/s

f :

The feed rate, μm/rev

r e :

The cutting edge radius in μm

θ t(t):

The slope angle of the tool movement

V x(t):

The velocity vector of the tool movement in x-direction

V y(t):

The velocity vector of the tool movement in y-direction

V t(t):

The transient tool velocity

TOC t (t) :

The transient thickness of cut as function of time

TOC max :

The maximum of transient thickness of cut

t A :

Tool engaging time at the point A

t A′:

Tool engaging time in previous cycle at the point A

t D :

Tool disengaging time at the point D

t P :

Toll disengaging time in the previous one-cycle at point P

t T :

Tool engaging time lies between the point A and B

ϕ s(t):

Transient shear angle as function of time

ϕ kc :

The constant shear angle of the CC-like process

ϕ kr :

The constant shear angle of the kinetic reverse process

β:

The friction angle

αo :

The constant rake angle

ε(t):

The transient shear strain

\( \dot{\varepsilon}(t) \) :

The transient shear strain rate

∆d:

The thickness between two sequences segmented chip

∆s:

The elongation of workpiece material during shear deformation

τ s(t):

The modified Johnson-Cook flow stress

A, B, C, n, m :

The constant Johnson-Cook parameters

F s(t):

The transient shear force

F R(t):

The transient resultant force

F c(t):

The transient principal force

F t(t):

The transient thrust force

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Funding

This study was supported by the Basic Science Research Program through the National Research Foundation of Korea (NRF) and funded by the Ministry of Science, ICT, and Future Planning [Grant Number NRF-2020R1A2B5B02001755].

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Authors and Affiliations

  1. Precision Machining Laboratory room 214, Department of Mechanical Engineering, Yeungnam University, 280 Daehak-Ro, Gyeongsan, Gyeongbuk, South Korea

    Rendi Kurniawan, Farooq Ahmed, Saood Ali, Gun Chul Park & Tae Jo Ko

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  1. Rendi Kurniawan
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  2. Farooq Ahmed
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  3. Saood Ali
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Contributions

Rendi Kurniawan: Writing – original draft, Methodology, Conceptualization, Investigation, Formal Analysis.

Farooq Ahmed: Resources.

Saood Ali: Resources.

Gun Chul Park: Validation.

Tae Jo Ko: Writing – review & editing, Supervision, Project Administration.

Corresponding author

Correspondence to Tae Jo Ko.

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Kurniawan, R., Ahmed, F., Ali, S. et al. Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V. Int J Adv Manuf Technol 117, 1739–1764 (2021). https://doi.org/10.1007/s00170-021-07831-8

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