Numerical investigations on the dynamic ploughing interaction in elliptical vibration cutting

Although elliptical vibration cutting demonstrates the promising application prospects in precision manufacturing process, its material removal and deformation mechanisms have complex time-varying characteristics due to the introduction of tool vibration. Moreover, the coupled characteristics of shearing force on tool rake face and ploughing force on tool flank provide the significant challenges for the experimental explorations of transient cutting mechanisms of elliptical vibration cutting. In this paper, a novel finite element simulation model is proposed to accurately capture the dynamic ploughing interactions between the tool flank and machined waviness in elliptical vibration cutting. The original workpiece surface is intentionally constructed as the ideal representation of the bottom of resultant cutting path for decoupling the ploughing interaction from the material shearing removal. The results indicates that the extrusion and friction forces acting on the flank both show linear dependence with the flank-waviness interference volume, which contributes to the understandings of underlying surface generation mechanism and the establishment of high-precision cutting force in elliptical vibration cutting.