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Numerical Simulations of Vibration Assisted Machining

Numerical Simulations of Vibration Assisted Machining. John Patten and Andre Williams Manufacturing Research Center Western Michigan University, Kalamazoo MI. Motivation of Project. UNCC: VAM Diamond Turning of Steel Tool 0.0005 mm cutting edge radius Zero degree rake angle

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Numerical Simulations of Vibration Assisted Machining

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  1. Numerical Simulations of Vibration Assisted Machining John Patten and Andre Williams Manufacturing Research Center Western Michigan University, Kalamazoo MI

  2. Motivation of Project • UNCC: VAM Diamond Turning of Steel • Tool • 0.0005 mm cutting edge radius • Zero degree rake angle • 10 degree clearance angle • Machining • Cutting speed 0.175 m/s • Depth of cut: 0.120 mm • Feed: 0.02 mm • VAM • Amplitude: 0.008 mm (8 micrometers, μm) • Frequency: 10,000 Hz

  3. Development of FEA Software • Third Wave Systems, Inc. • WMU worked with TWS to incorporate a VAM module capability into their commercial machining simulation software, AdvantEdge • Interest in simulating work by Dow et al. at the PEC @ NCSU: SiC

  4. Basic Model Parameters • Base Case: Diamond Tool, Steel: 12L14 • Tool: • Cutting edge radius: 0.002 (0.001) [0.0005] mm • Rake Angle: zero degrees • Clearance Angle: 10 degrees • Cutting Speed: 1 m/s (0.5 and 0.25) [0.175] • Feed: 0.02 mm (uncut chip thickness) • VAM: 10,000 Hz (0, 2, 4, 8 μm amplitude) • Thermal Model/Conditions: On and Off

  5. Simulated Process Variables

  6. FEA Simulation results • Variables • Amplitude • Speed • Output • Temperature • Forces

  7. 1 m/s VAM Simulation with Thermal ON and 0 Amplitude

  8. .5 m/s VAM Simulation with Thermal ON and 0 Amplitude

  9. .5 m/s speed VAM Simulation with Thermal ON and.002 amplitude

  10. 1 m/s VAM Simulation with Thermal ON and 0.008 Amplitude

  11. .25 m/s speed VAM Simulation with Thermal ON and .008 amplitude

  12. VAM Simulation with Thermal ON, .004 Amplitude, and 1 m/s

  13. Tool Temperature

  14. Maximum Workpiece Temperature

  15. Work piece Temperature

  16. Thermal ModelOn/Off ComparisonAverage/Dynamometer Force

  17. Cutting Force, 4 micrometer vib. amp., 1 m/s cutting speed

  18. Averaged Peak Cutting Forces

  19. Cutting Force Vs. Amplitude

  20. Cutting Force Vs. Cutting Speed

  21. Cutting Force, Amplitude & Speed

  22. Future Work • Silicon Carbide: SiC (CVD coated) • Aluminum Titanium Carbide: AlTiC • Cutting Fluids • Thermal effects • Friction effects • Chip formation and breakage • Tool Geometry • Tool Wear

  23. Acknowledgements • NSF • TWS • Jerry Jacob (WMU)

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