Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element Method
The objective of this work is to analyze the influence of the vibration-assisted turning process on the machinability of S235 carbon steel. During the experiments using this vibrational machining process, the vibrational amplitude and frequency of the cutting tool were adjusted to drive the tool tip...
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doaj-2aa38cb7406d449294b1e3317b242e832020-11-25T02:18:25ZengMDPI AGMaterials1996-19442020-01-0113356710.3390/ma13030567ma13030567Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element MethodLuis C. Flórez García0Hernán A. González Rojas1Antonio J. Sánchez Egea2Department of Mechanical Engineering, Universidad Tecnológica de Pereira, Risaralda 660003, ColombiaDepartment of Mechanical Engineering (EPSEVG), Universitat Politécnica de Catalunya, 08800 Barcelona, SpainDepartment of Mechanical Engineering (EEBE), Universitat Politècnica de Catalunya, 08019 Barcelona, SpainThe objective of this work is to analyze the influence of the vibration-assisted turning process on the machinability of S235 carbon steel. During the experiments using this vibrational machining process, the vibrational amplitude and frequency of the cutting tool were adjusted to drive the tool tip in an elliptical or linear motion in the feed direction. Furthermore, a finite element analysis was deployed to investigate the mechanical response for different vibration-assisted cutting conditions. The results show how the specific cutting energy and the material’s machinability behave when using different operational cutting parameters, such as vibration frequency and tool tip motion in the <i>x</i>-axis, <i>y</i>-axis, and elliptical (<i>x</i>-<i>y</i> plane) motion. Then, the specific cutting energy and material’s machinability are compared with a conventional turning process, which helps to validate the finite element method (FEM) for the vibration-assisted process. As a result of the operating parameters used, the vibration-assisted machining process leads to a machinability improvement of up to 18% in S235 carbon steel. In particular, higher vibration frequencies were shown to increase the material’s machinability due to the specific cutting energy decrease. Therefore, the finite element method can be used to predict the vibration-assisted cutting and the specific cutting energy, based on predefined cutting parameters.https://www.mdpi.com/1996-1944/13/3/567vibration-assisted turningmachinabilityspecific cutting energyfinite element methodelliptical motionduty cycle |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Luis C. Flórez García Hernán A. González Rojas Antonio J. Sánchez Egea |
spellingShingle |
Luis C. Flórez García Hernán A. González Rojas Antonio J. Sánchez Egea Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element Method Materials vibration-assisted turning machinability specific cutting energy finite element method elliptical motion duty cycle |
author_facet |
Luis C. Flórez García Hernán A. González Rojas Antonio J. Sánchez Egea |
author_sort |
Luis C. Flórez García |
title |
Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element Method |
title_short |
Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element Method |
title_full |
Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element Method |
title_fullStr |
Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element Method |
title_full_unstemmed |
Estimation of Specific Cutting Energy in an S235 Alloy for Multi-Directional Ultrasonic Vibration-Assisted Machining Using the Finite Element Method |
title_sort |
estimation of specific cutting energy in an s235 alloy for multi-directional ultrasonic vibration-assisted machining using the finite element method |
publisher |
MDPI AG |
series |
Materials |
issn |
1996-1944 |
publishDate |
2020-01-01 |
description |
The objective of this work is to analyze the influence of the vibration-assisted turning process on the machinability of S235 carbon steel. During the experiments using this vibrational machining process, the vibrational amplitude and frequency of the cutting tool were adjusted to drive the tool tip in an elliptical or linear motion in the feed direction. Furthermore, a finite element analysis was deployed to investigate the mechanical response for different vibration-assisted cutting conditions. The results show how the specific cutting energy and the material’s machinability behave when using different operational cutting parameters, such as vibration frequency and tool tip motion in the <i>x</i>-axis, <i>y</i>-axis, and elliptical (<i>x</i>-<i>y</i> plane) motion. Then, the specific cutting energy and material’s machinability are compared with a conventional turning process, which helps to validate the finite element method (FEM) for the vibration-assisted process. As a result of the operating parameters used, the vibration-assisted machining process leads to a machinability improvement of up to 18% in S235 carbon steel. In particular, higher vibration frequencies were shown to increase the material’s machinability due to the specific cutting energy decrease. Therefore, the finite element method can be used to predict the vibration-assisted cutting and the specific cutting energy, based on predefined cutting parameters. |
topic |
vibration-assisted turning machinability specific cutting energy finite element method elliptical motion duty cycle |
url |
https://www.mdpi.com/1996-1944/13/3/567 |
work_keys_str_mv |
AT luiscflorezgarcia estimationofspecificcuttingenergyinans235alloyformultidirectionalultrasonicvibrationassistedmachiningusingthefiniteelementmethod AT hernanagonzalezrojas estimationofspecificcuttingenergyinans235alloyformultidirectionalultrasonicvibrationassistedmachiningusingthefiniteelementmethod AT antoniojsanchezegea estimationofspecificcuttingenergyinans235alloyformultidirectionalultrasonicvibrationassistedmachiningusingthefiniteelementmethod |
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1724882292441088000 |