Damping Impact on 1-Dimensional Ultrasonic Vibration-Assisted Turning Machining

Abstract

In ultrasonic vibration-assisted turning (UVAT), vibration is one of the critical factors that causes noise during machining and affects cutting tool life, machining accuracy and workpiece surface quality. Vibration generated by piezoelectric actuators tends to transmit undesired vibration on the edge of the cutting tool and tool post. This situation hinders the maximization of vibration energy usage in the cutting tool. Thus, this paper investigated the vibration performance in the cutting tool by adding an isolator pad as damping element in the static zone of a tool holder to reduce the resonance generated during the machining process. The static, vibration and surface roughness analysis has been performed to determine the impact of damping on the machining performance. The results revealed a significant improvement in surface roughness where the best Ra for UVAT was 0.38 μm. In addition, vibration and static analysis showed the application of isolator pad capable of reducing 80% of energy loses and a supporter to increase the displacement, respectively. Ultimately this innovative solution can play an important role in improving UVAT performance.