Modeling and analysis of tool-chip contact model during quasi-intermittent vibration assisted swing cutting based on two-zone theory

• Published in: International journal of advanced manufacturing technology Vol. 120; no. 1-2; pp. 615 - 626
• Main Authors: Zhang, Limin, Li, Nan, Lu, Mingming, Zhou, Jiakang, Jin, Yubo, Liu, Yuyang
• Format: Journal Article
• Language: English
• Published: London Springer London 01.05.2022; Springer Nature B.V
• Subjects: CAE) and Design; Coefficient of friction; Computer-Aided Engineering (CAD; Cutting force; Cutting parameters; Cutting speed; Cutting tools; Cutting wear; Engineering; Friction; Friction reduction; Industrial and Production Engineering; Machining; Mechanical Engineering; Media Management; Modelling; Original Article; Physical properties; Shear zone; Surface properties; Tool wear; Vibration analysis; Workpieces; QVASC; Titanium alloy processing; Contact area; Tool-chip contact characteristics
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-021-08620-z

Quasi-intermittent vibration assisted swing cutting (QVASC) is a new processing method with the advantages of quasi-intermittent cutting and friction reversal. In the cutting process, it is important to study the tool-chip friction characteristics for reducing the cutting force, tool wear and improving the surface quality of the workpiece. This paper divides the tool-chip contact interface (TCI) based on the two-zone analysis modeling method during QVASC. The proposed model includes the primary shear zone, the secondary shear zone and the TCI. The friction coefficient equations of sticking, sliding and the whole part are expressed, and the physical properties of each zone in the machining process are comprehensively described. The theoretical simulation and experimental verification are carried out, and it is found that the proposed model is in good agreement with the experimental results. When the cutting speed is 7.85–11.78 m/min, the theoretical and experimental cutting force error of QVASC is less than 15%. The results show that the model provides an analysis method that can effectively predict the contact characteristics of the TCI during QVASC processing. The cutting force of QVASC is significantly less than traditional continuous cutting, which can reduce the cutting force.