Development of ultrasound elliptical cutting device and study on its cutting performance

Based on the mechanism of single-excitation elliptical vibration and considering the relationship between ultrasonic vibration direction and cutting direction, two types of elliptical vibration cutting device were developed according to the different installation methods of cutting insert. Through vibration modal analysis and harmonic response analysis, tilted slots were chosen to be opened on the small end of the step transformer with cone transition and the position and geometrical parameters of the tilted slots were optimized. Simulation result shows the ideal state of the ultrasonic elliptic vibration can be formed on the tool nose. By means of the developed two types of cutting setup, a series of contrast experiments on cutting force and micro features in machined surface were carried out and the cutting performance of the two different devices were comparatively analyzed. Research result shows that the direction of elliptical vibration has obvious effect on the cutting performance. Lower cutting force and better machined surface can be obtained if the long axial of the elliptical vibration is in the same direction of the main cutting force.