Theoretical and experimental investigation of the frictional behavior of the tool–chip interface in ultrasonic-vibration assisted turning

The frictional behavior of the tool–chip interface has a significant role in the cutting mechanics. The frictional and normal forces, the contact length between the cutting tool and chip, the coefficient of friction and the stress distribution are the influential parameters. The behavior of the tool–chip interface in ultrasonic-vibration assisted cutting is different from conventional cutting and needs to be investigated. The ultrasonic-vibration assisted cutting has several advantages compared with conventional process. In the present study a frictional model has been developed for studying the above mentioned parameters and predicting the tool–chip behavior in ultrasonic-vibration assisted turning at different cutting speeds and vibration amplitudes. The results have been verified by experiments.

► We developed the theory of frictional behavior in ultrasonic assisted turning UAT.
► The developed theory was verified by experiments.
► Time-dependent relative cutting speed was considered for developing the theory.
► Friction coefficient, μ, in UAT was higher than conventional turning.
► Lower UAT cutting force is due to reduction of normal/friction force ratio.