Research of Tool Nose Radius in Ultrasonic Vibration Cutting for Difficult-to-cut Materials

Abstract

Ultrasonic vibration cutting (UVC) as an advanced technique has been widely used in order to increase productivity and stabilities in machining of difficult-to-cut materials. The authors presented a chatter monitoring and signal processing system for turning a slender workpiece. A suitable tool nose radius prevents the tool fracturing occurrence so that the instability of the machining process is markedly reduced by applying UVC. When employing the novel machining method of online monitoring vibration signals and adjusting cutting parameters in real time, there is no occurrence of chatter and the machining accuracy is close to predicted amplitude of vibration during the whole cutting process. At the same time, the tool life improves to some extent.