FE simulation of linear and elliptical ultrasonic vibrations in turning of Inconel ۷۱۸

چکیده مقاله

Utilization of ultrasonic vibrations in turning operation is an advanced method to improve processing of materials. The aim of the present study was to develop a finite element model in order to investigate the effect of ultrasonic vibrations on machinability factors in turning of Inconel 718. Conventional turning in addition to linear and elliptical ultrasonic-assisted turning were simulated and the effect of these processes on cutting forces, shear angle , chip thickness, sticky zone , and temperature distributed on tool rake face was analyzed. Besides, the experimental tests were conducted and the cutting forces have been measured to validate the simulation outputs. As a result, analysis of chip formation shows that the values higher than 45 for shear angle is achieved when elliptical vibration is added to the cutting process. Fur thermore , increase of shear angle coupled with decrease of temperature on tool rake face causes the sticky zone in tool–chip contact length to be reduced compared to the conventional turning. Moreover, the influence of cutting speed on tool–chip engagement time in ultrasonic-assisted turning is simulated.