3D finite element analysis of ultrasonically assisted turning

Ultrasonically assisted turning (UAT) is an advanced machining technique, where high-frequency vibration is superimposed on the movement of a cutting tool. Compared to conventional turning (CT), this technique allows significant improvements in processing intractable materials. The paper presents a recently developed 3D model of UAT as an extension to our initial 2D model [A.V. Mitrofanov, V.I. Babitsky, V.V. Silberschmidt, J. Mater. Process. Technol. 153–154 (2004) 233]. This model allows studying various 3D effects in turning, such as oblique chip formation, as well as to analyse the influence of tool geometry on process parameters, e.g. cutting forces and stresses generated in the workpiece material. The FE model is used for transient, coupled thermomechanical simulations of elasto-plastic materials under conditions of both UAT and CT. It is used to study the effect of cutting parameters (such as the cutting speed, depth of cut and feed rate) and friction on UAT and CT. Numerical results are validated by experimental tests.