Experimental investigation of transverse vibration-assisted orthogonal cutting of AL-2024

In the conventional use of vibration-assisted machining the vibratory motion is applied to the tool either linearly along the direction of the cutting velocity or elliptically in the plane containing the cutting velocity and surface normal. In contrast to this, this study investigates vibrations that are applied along the cutting edge and perpendicular to the cutting velocity. Such a vibratory motion is expected to provide a small sawing action that will enhance the ductile fracture occurring ahead of the cutting tool as the chip separates from the bulk work material. This enhancement in fracture will then contribute to reducing the chip thickness and cutting forces. Also, the sawing action reduces the imprint left behind by the cutting tool leading to a better surface finish. To confirm these predictions orthogonal cutting with the assistance of transverse vibrations applied to the cutting tool are performed on Al-2024 tubes using a carbide cutting tool. Experiments are performed at different conditions of cutting speeds, feeds and amplitudes of vibration at a fixed vibration frequency of 40 kHz. Cutting forces, chip thickness, and surface finishes are measured and compared with similar cutting conditions without application of vibration. In general, a reduction in cutting forces and feed forces is observed when transverse vibrations are applied. Chip thickness is also reduced and surface finish is improved upon application of vibration. Some explanations are offered to support these results.