Finite element modeling of ultrasonic assisted turning with external heating

Abstract

Ultrasonic assisted turning (UAT) has shown significant advantages over conventional turning (CT) due to its intermittent cutting nature. There have been some issues related to the machining responses which have not been much explored. Most of the issues are driven by the cutting force which is a function of material properties. Present article gives finite element modeling (FEM) of UAT with external heating at different temperature assuming it alters the material properties particularly in terms of material softening. The objective is to analyze the effect of temperature, vibration amplitude, frequency and cutting speed on the machining responses using two different materials SS304 and low carbon (0.08%) steel. The parameters such as feed rate, tool rake angle and nose radius are kept constant. The shear angle, cutting force, and thrust force are determined as output responses. The FEM results show a significant effect of external heating in shear angle, cutting force and thrust force for both SS304 and low carbon steel. It is observed that as the temperature increases, there is an increment in shear angle and reduction in average cutting force and average thrust force. Moreover, a significant improvement in machining forces and shear angle was also noticed at a higher value of amplitude, cutting speed and frequency.