Tool Wear Prediction and Surface Improvement in Vibration Cutting

Prolongation of tool life in metal cutting is an effective factor to produce lower cutting forces and better machined surfaces. In this study, the influence of ultrasonic vibration is analyzed using experimental and numerical methods. Accordingly, turning tests are carried out on an AISI 4140 steel bar in two types of machining: conventional and ultrasonic-assisted turning. After verification of the developed model, tool wear results are discussed with respect to analysis of heat and stress distributed on tool faces. Finally, it was revealed that periodic movement of the cutting tool in vibratory turning resulted in reduced contact time, resulting in lower heat conduction from the deformed chip to tool rake face. As a result, lower wear has been propagated on tool faces compared to a tool worn in conventional turning. In addition, the effect of cutting parameters on surface roughness is investigated by measurement and 3D analysis of surface topography.