Title: Assessment of high and low frequency vibration assisted turning with material hardness

Authors: Naresh Kumar Maroju; P. Vamsi Krishna; Xiaoliang Jin

Addresses: School of Mechanical and Aerospace Engineering, Oklahoma State University, Stillwater, 74075, USA ' Department of Mechanical Engineering, National Institute of Technology Warangal, Telangana, 506004, India ' School of Mechanical and Aerospace Engineering, Oklahoma State University, Stillwater, 74075, USA

Abstract: Vibration assisted turning (VAT) is a process to implement external vibrations in conventional turning (CT) process in order to improve overall machining performance. In this paper, the machinability of both high frequency vibration assisted turning (HVAT) and low frequency vibration assisted turning (LVAT) is investigated in machining typical engineering materials, including AISI 52100, AISI 4340, IN-100, Ti6Al4V, AISI 1050 and Al-2024-T-351. Both HVAT and LVAT are assessed in terms of effective stresses, forces, temperature and residual stresses and compared to CT. A 3D finite element model is developed for machining Ti6Al4V, with simulated temperature and cutting force experimentally validated. This model is used to perform the evaluation of machining processes for other materials. In addition, surface finish and tool wear analyses are performed for AISI 4340 and Al 2024-T-351 to evaluate the applicability of LVAT compared to CT. It is found that HVAT and LVAT are able to achieve significant improvements compared to CT. Reduction of cutting forces, stresses and temperature is observed in the VAT process. The applicability of LVAT is found to be limited by hardness of the material.

Keywords: vibration assisted turning; material hardness; low frequency vibration; ultrasonic; FEA; finite element analysis; simulation; residual stress; high frequency vibration; Ti6Al4V; titanium alloys; surface finish; tool wear; cutting forces; stress; temperature.

DOI: 10.1504/IJMMM.2017.082903

International Journal of Machining and Machinability of Materials, 2017 Vol.19 No.2, pp.110 - 135

Received: 21 Oct 2015
Accepted: 17 Jan 2016

Published online: 15 Mar 2017 *

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