Title: Estimation of cutting forces in conventional and ultrasonic-vibration assisted turning using inverse modelling

Authors: U.S. Dixit; V. Yadav; V. Sharma; P.M. Pandey; A. Roy; V.V. Silberschmidt

Addresses: Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati-781 039, India ' Department of Mechanical Engineering, North Eastern Regional Institute of Science and Technology, Nirjuli, 791 109, India ' Department of Mechanical Engineering, Indian Institute of Technology Delhi, New Delhi-110 016, India ' Department of Mechanical Engineering, Indian Institute of Technology Delhi, New Delhi-110 016, India ' Wolfson School of Mechanical, Electrical and Manufacturing Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, UK ' Wolfson School of Mechanical, Electrical and Manufacturing Engineering, Loughborough University, Loughborough, Leicestershire LE11 3TU, UK

Abstract: In this work, cutting forces in conventional and ultrasonic-vibration assisted turning are estimated using an inverse method to evaluate the velocity-dependent friction and fracture toughness based on a few tests in conventional turning. The inverse methodology requires the data on cutting and feed forces at two specified cutting speeds. Analytical expressions are employed to estimate the cutting forces in conventional as well as ultrasonic-vibration assisted turning. The suggested method was verified with experimental data. The validation of the direct model with the finite-element results available in the literature was also carried out. A sensitivity analysis revealed a significant effect of friction on cutting forces. Thanks to its simplicity, the proposed procedure may find a good application in industrial practice.

Keywords: cutting forces; ultrasonic-vibration assisted turning; friction; inverse method; fracture toughness; machining; Johnson-Cook model; Ti-6246; 4340 hardened steel; orthogonal cutting.

DOI: 10.1504/IJASMM.2017.089923

International Journal of Additive and Subtractive Materials Manufacturing, 2017 Vol.1 No.3/4, pp.265 - 289

Received: 09 May 2017
Accepted: 29 Sep 2017
Published online: 25 Feb 2018 *

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