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Numerical analysis in ultrasonic elliptical vibration cutting (UEVC) combined with electrical discharge assistance (EDA) for Ti6Al4V

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Abstract

This paper reports the numerical analysis results of ultrasonic elliptical vibration cutting (UEVC) combined with the electrical discharge assistance (EDA), called UEVC + EDA. UEVC delivers decreasing cutting forces, repressing side-burrs, and lowering tool wear. EDA is a cutting technique using a pulsed spark to remove material using thermal energy. Difficult-to-cut materials, such as Ti-6Al-4 V, can be cut effectively by combining these two techniques. A numerical study was performed using ABAQUS finite element analysis (FEA) software by investigating the von Mises stress, cutting forces, and temperature. Numerical analysis was carried out by modifying the ultrasonic vibration frequency, distance of the discharge pulse, discharge voltage, and discharge pulse radius. UEVC + EDA was compared numerically and experimentally with regular cutting (NC) and UEVC in terms of cutting force and tool temperature. The results showed that the UEVC + EDA method could improve the cutting condition by reducing the cutting force and von Mises stress and increasing the tool temperature.

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Funding

The Basic Science Research Program supported this research through the National Research Foundation of Korea (NRF), 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, Gyeongsan, South Korea

    Rendi Kurniawan, Moran Xu, Gun Chul Park, Ye In Kwak, Jielin Chen & Tae Jo Ko

  2. Faculty of Mechanical and Electromechanical Engineering, Hunan University of Science and Technology, Taoyuan Road, Xiangtan, Hunan, China

    Chang Ping Li

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  1. Rendi Kurniawan
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Contributions

Rendi Kurniawan: Writing — original draft, conceptualization, methodology, formal analysis, and software; Moran Xi, Jielin Chen: visualization, investigation; Chang Ping Li: validation; Gun Chul Park, Ye In Kwak: project administration, resources; Tae Jo Ko: writing – review and editing, supervision, funding acquisition.

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Kurniawan, R., Xu, M., Li, C.P. et al. Numerical analysis in ultrasonic elliptical vibration cutting (UEVC) combined with electrical discharge assistance (EDA) for Ti6Al4V. Int J Adv Manuf Technol 120, 471–498 (2022). https://doi.org/10.1007/s00170-022-08724-0

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