Chip control in turning with synchronization of spindle rotation and feed motion vibration

• Published in: Precision engineering Vol. 53; pp. 38 - 45
• Main Authors: Miyake, Akihito, Kitakaze, Ayako, Katoh, Seiko, Muramatsu, Masahiro, Noguchi, Kenji, Sannomiya, Kazuhiko, Nakaya, Takaichi, Sasahara, Hiroyuki
• Format: Journal Article
• Language: English
• Published: Elsevier Inc 01.07.2018
• Subjects: Chip control; Cutting force; LFV; Low frequency; Turning; Vibration cutting; Turning; Chip control; Vibration cutting; Low frequency; LFV; Cutting force
• ISSN: 0141-6359; 1873-2372
• DOI: 10.1016/j.precisioneng.2018.02.012

[Display omitted] •Motion conditions for chip breaking of the LFV proposed as a new vibration cutting method was geometrically derived.•The LFV is not constrained in processing shape unlike conventional vibration cutting.•The specific cutting force of LFV when the cutting force was decreased compared with that of conventional cutting at the same feed rate.•Experiments show the effectiveness of LFV for difficult-to-cut materials such as stainless steel, which tends to generate long chips. In turning process, long continuous chips are often generated and become entangled in both the tool and the machine. It can cause scratches on the product surface, adversely affect the tool life, or cause the machine to stop. To solve the problems in the turning process caused by long continuous chips, Low frequency vibration-cutting (LFV) was developed. LFV applies the vibration in the tool feed direction and can synchronously control the vibration in the tool feed direction and the spindle rotation. The vibration is composed of a combination of the two vibration axes, the X axis and the Z axis, of the lathe. Therefore, unlike in conventional vibration cutting, LFV has a big advantage in that it can be applied to all shapes processed with a lathe such as a taper or an arc. In this paper, we proposed a motion conditions formula for breaking chips using the operating parameters of LFV, and carried out cutting experiments on SS304 stainless steel using LFV and conventional cutting. As a result, it was found that LFV can discharge chips of a shape corresponding to the motion conditions. The cutting force of LFV drew a trapezoidal shape, and it was confirmed that periods during which the cutting force became zero periodically appeared. It was revealed that the specific cutting force of LFV when the cutting force becomes maximum was decreased compared with that of conventional cutting at the same feed rate. These results indicated that LFV can be useful for difficult-to-cut materials such as SS304.