Characteristics of vibration cutting technology and its application (Figure)

1 Introduction

Vibration cutting is an advanced manufacturing technology developed in the 1960s. It applies a high-frequency vibration to a conventional cutting tool to make intermittent contact between the tool and the workpiece, thus making the traditional cutting mode fundamental. Variety. Since this change solves the problems inherent in the conventional cutting process, such as vibration during cutting and thermal deformation of the cutting, an excellent cutting effect is obtained. So far, although there are some differences in the selection of some parameters in the interpretation of some phenomena of vibration cutting in the world, the process effect is consistently recognized. As a new technology in the processing of precision machining and difficult-to-machine materials, it has penetrated into various processing fields, and various composite processing methods have emerged, which has made the traditional processing technology a leap. Studies have shown that, because it can effectively solve the problems of machining and precision machining of difficult-to-cut materials within a certain range and has a series of characteristics in processing, it has attracted more and more attention and has attracted the attention of countries all over the world. .

2. Ordinary cutting and vibration cutting

In normal cutting, cutting is done by the relative motion of the tool and the workpiece. The formation of chips and machined surfaces is essentially the process by which the workpiece material is squeezed by the tool, creating elastic and plastic deformation, separating the chips from the parent (see Figure 1). In the ordinary cutting in which the tool does not leave the cutting, the function of the tool includes two aspects: one is the action of the blade; and the other is the blade face forming the blade. Due to the local pressure at the point where the blade is in contact with the object to be cut,

Separate the cut objects. The knives support the cut while cutting, facilitating this separation. In ordinary cutting, along with the formation of chips, due to the extrusion and friction between the chips and the tool, large cutting forces will inevitably occur, and the cutting temperature will cause harmful effects such as tool wear and cutting vibration. .

Figure 1 Ordinary cutting

Based on this idea, a new cutting method, vibration cutting, has been created in the fight against harmful self-excited vibration phenomena. Vibration cutting is a method of obtaining a special cutting effect by applying a regular, controllable vibration on the cutting tool to periodically change the cutting speed and the amount of the backing knife (see Figure 2). Vibration cutting changes the space and time between the tool and the material to be machined, thus changing the machining (cutting) mechanism, achieving the purpose of reducing cutting force, cutting heat, and improving processing quality and efficiency. Vibration cutting can be divided into high-frequency vibration and low-frequency vibration according to the added frequency. The low-frequency vibration only changes the formation condition of the chip, which is mainly used to solve the problem of chip breaking and a series of problems related to it. Ultrasonic vibration (high-frequency vibration) cutting has caused significant changes in the chip formation mechanism, which can improve the machinability of the material to be processed, improve tool life and workpiece processing quality. The effect of ultrasonic machining comes from the separation movement between the tool and the workpiece, ie it is a pulsed intermittent cutting process. Therefore, as a new technology in the processing of precision machining and difficult-to-machine materials, its cutting effect has been widely recognized by all countries in the world, and it is considered to be a leap in traditional processing technology.

Figure 2 Vibration cutting

The flow of the vibration cutting system is: the ultrasonic power source outputs a high-power ultrasonic frequency AC signal, and the transducer converts the electric energy into mechanical vibration of the same frequency, and the amplitude is amplified by the horn, thereby driving the tool vibration. Its composition is shown in Figure 3. The vibration system is fixed on the tool holder. The left end of the knife bar is the blade, and the right end is the vibration drive center. The transducer and the horn convert the longitudinal vibration into the lateral vibration of the bending bar.

3. Characteristics of vibration cutting and analysis of process effects

(1) Characteristics of vibration cutting

Vibration cutting can greatly reduce the cutting force, reduce friction heat, improve tool life and reduce the surface roughness of the machined surface, which has the following characteristics:

Figure 3 vibration system composition diagram

1. workpiece 2. blade 3. tool holder 4. knife bar 5. horn 6. transducer 7. circulating cooling water

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